Dodge - Stratus - Workshop Manual - 1997 - 1997

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Factory Workshop Manual Make Dodge Model Stratus Engine and year V6-2.5L VIN H (1997) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations System Relay And Pump Motor Relay Box Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay ABS Main Relay: Description and Operation ABS System Relay CIRCUIT OPERATION The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor, and terminates at the right frame rail. when the system is operating normally, power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the right frame rail. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the A20 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay > Page 9 ABS Main Relay: Description and Operation ABS System Relays System Relay And Pump Motor Relay Box SYSTEM RELAY The main purpose of the system relay is to put the Antilock Brake System (ABS) into a stand-by mode for ABS operation. The System Relay is energized by the Controller Antilock Brake (CAB) shortly after the ignition switch is turned on. When Energized - by the CAB, the System Relay turns off the ABS warning lamp and provides 12 volts to the CAB. This voltage can then be used by the CAB to energize the Decay Solenoids during ABS braking. When energized, the System Relay also provides the Pump/Motor Relay coil with 12 volts. The ground path to the Pump/Motor Relay is completed by the CAB during ABS braking. When De-energized - the ABS warning lamp is illuminated, voltage to the Decay Solenoids is cut off, and the Pump/Motor Relay is prevented from energizing. Typically, the System Relay is de-energized by the CAB when a fault is detected that requires turning ABS off. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description Brake Fluid Pump Relay: Description and Operation Description System Relay And Pump Motor Relay Box PURPOSE Pump/Motor power is supplied by the Pump/Motor Relay. The pump motor relay is also part of the relay box mounted to the Hydraulic Control Unit (HCU). If pump/motor relay replacement is required, it is also only serviced by the replacement of the relay box assembly. FUNCTION Voltage for the 12 volt side of the relay coil is provided by the System Relay. The ground path through the relay coil is completed by the Controller Antilock Brake (CAB) during Antilock Brake System (ABS) braking. The relay contacts are closed when the relay is energized. This provides 12 volts to the pump/motor as needed during ABS braking. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description > Page 14 Brake Fluid Pump Relay: Description and Operation Circuit Operation CIRCUIT OPERATION The ABS pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B120 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B10 from the relay box powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Controller Antilock Brake Location CAB 60-Way Wiring Harness Connector The CAB is located in the right front corner of the engine compartment. It is mounted to the vehicle using an integral mounting bracket, which is attached by 2 bolts, to the inner fender and the front crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 18 Electronic Brake Control Module: Description and Operation Controller Antilock Brake Location PURPOSE The Controller Antilock Brakes (CAB) is a microprocessor based device which monitors the ABS system during normal braking and controls it when in an ABS stop. The CAB is mounted in the right front corner of the engine compartment using an integral mounting bracket to attach it to the inner fender. The CAB uses a 60 way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the Run or ON position. NOTE: The CAB is not on the Chrysler Collision Detection (CCD) bus. THE PRIMARY FUNCTIONS OF THE CAB - Detect wheel locking tendencies. - Control fluid modulation to the brakes while in ABS mode. - Monitor the system for proper operation. - Provide communication to the DRB scan tool while in diagnostic mode. The CAB Continuously Monitors - the speed of each wheel through the signals generated at the Wheel Speed Sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABS System Is Constantly Monitored - by the CAB for proper operation. If the CAB detects a fault, it will turn on the Amber ABS Warning Lamp and disable the ABS braking system. The normal Non ABS braking system will remain operational. The CAB Contains A Self-diagnostic Program - which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected. Faults are then stored in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB and displayed through the DRB scan tool. These fault messages will remain in the CAB memory even after the ignition has been turned off. The fault messages can be cleared by using the DRB scan tool, or they will be automatically cleared from the memory after a minimum of 3500 vehicle miles are accumulated. CONTROLLER ANTILOCK BRAKE INPUTS - Four wheel speed sensors. - Stop lamp switch. - Ignition switch. - System relay voltage. - Ground. - Pump/Motor Relay Monitor. - Diagnostics Communications. CONTROLLER ANTILOCK BRAKE OUTPUTS - Decay Solenoids. - ABS warning lamp. - System relay actuation. - Diagnostic communication (Single line ISOK). - Pump motor relay actuation. - Brake Lamp (Low Fluid/Pressure). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 19 Electronic Brake Control Module: Service and Repair Controller Antilock Brake Location REMOVE 1. Turn vehicle ignition off. CAB 60-Way Wiring Harness Connector 2. Disconnect the wiring harness 60 way connector from the Controller Antilock Brake Module (CAB). Verify that the vehicle ignition is off before removing the 60 way connector. CAB Bracket To Engine Compartment Mounting 3. Remove the 2 bolts attaching the CAB mounting bracket to inner fender and front upper crossmember. 4. Remove the CAB from the vehicle. INSTALL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 20 1. Install the CAB and the mounting bracket assembled, on the right inner fender of the vehicle. 2. Install the 2 bolts mounting the CAB bracket to the vehicle. Tighten both mounting bolts to a torque of 9 Nm (75 inch lbs.). 3. Install 60-way wiring harness connector into the CAB 60-way connector by hand until seated as far as possible. Then use CAB connector retaining bolt to fully seat wiring harness connector into the CAB. 4. Tighten the 60-way connector retaining bolt to a torque of 4 Nm (35 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 25 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 26 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 27 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 28 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation Blower Motor Relay: Description and Operation This system uses no blower motor relay. Motor is controlled by the fan control switch in the heater control head and by the blower motor resistor block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center Relay is in the Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation Control Module HVAC: Description and Operation SYSTEM OPERATION HVAC Control Module HVAC Control Module The rear window control switch and circuit are integrated into the HVAC control module. When actuating the switch it sends a ground signal to the Body Control Module (BCM). The BCM actuates the relay allowing current to flow through the grid lines for ten minutes upon initial actuation. Then 5 minutes with each subsequent actuation or until either the switch or ignition is turned off. An indicating lamp illuminates the rear window defogger switch. CIRCUIT OPERATION A/C - Heater Control The air conditioning-heater system is controlled by the Body Control Module (BCM). The BCM sends out voltage to the A/C-Heater control on circuit C58. The control uses resistors to internal to the control. These resistors are connected to the Z2 ground circuit. When the operator requests a function in the system the BCM measures the voltage drop, on circuit C58, and activates the mode actuator door to the proper position. A separate A/C switch is used in the system. This switch works the same as the mode actuator switches. When the operator presses the switch the BCM measures the voltage drop in the C21 circuit and activates the proper functions. Internal to the A/C-Heater control the A/C switch is connected to the blower motor switch. This allows the A/C system to only operate when the blower switch in an ON position. Ground for the A/C switch is provided through the blower motor switch to the Z1 circuit. This circuit terminates at the instrument panel left side cowl. A Light Emitting Diode (LED) is connected in the C21 circuit and illuminates when the A/C system is operating. Illumination lamps and LED's are internal to the control. These are controlled by the BCM. The E2 circuit from the BCM provides the voltage to the control for lamp and LED illumination. Ground for the lamps and LED's is provided on the Z1 circuit which terminates at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Page 39 Control Module HVAC: Service and Repair Fig 29 Control Module NOTE: The control module is located below the radio. REMOVAL 1. Place the ignition key in the OFF position before removing control module. 2. Remove trim bezel. Fig 30 Control Module Screws 3. Remove cluster hood bezel retaining screws in the trim bezel opening. 4. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws. 5. Remove the cubby bin/cigar lighter bezel and wiring. 6. Remove the control module retaining screws. Fig 31 Control Module At Bezel Opening Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Page 40 7. Drop the A/C control module into the cigar lighter/cubby bin bezel opening. Then disconnect the wiring on the rear of the control module. 8. Release the cable clips from the top of the control module. Retain the clips for future use. Then disconnect the temperature control and recirculation control cables. 9. Remove the control module. INSTALLATION For installation reverse the above procedures. Verify that the cables are properly adjusted and the module is seated properly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation SYSTEM OPERATION Headlamp Time Delay System The optional Headlamp Time Delay system is controlled by the Body Controller (BC) and a relay located in the junction block. The headlamp time delay system can be activated by turning ON the headlamps when the engine is running, turn OFF the ignition switch, then turn OFF the headlamp switch. The BC will allow the headlamps to remain ON for 90 seconds before they automatically turn off. Refer to the Owner's Manual for more information. CIRCUIT OPERATION Headlamp Delay The headlamp delay uses a relay located in the junction block. Power for the relay is supplied on circuit A3. This circuit powers the coil and contact sides of the relay and is protected by a 40 amp fuse located in the Power Distribution Center (PDC) cavity 15. The relay is activated by the operator turning OFF the ignition with the headlamps ON. The Body Control Module (BCM) controls the ground for the coil side of the relay and the amount of time the headlamps stay ON. Circuit G50 connects the coil side of the relay to the BCM. When the relay is energized, the contacts in the relay CLOSE connecting circuits A3 and L4. Circuit L4 is used to power the fuses used for low-beam headlamp operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Service and Repair Headlamp Control Module: Service and Repair The headlamp module contains the park and turn signal lamps and is serviced as an assembly. REMOVAL 1. Release hood latch and open hood. Headlamp Module 2. Remove screws holding headlamp module to radiator closure panel. 3. Separate headlamp module from radiator closure panel. 4. Disengage wire connector from back of head- lamp bulb. 5. Rotate Park lamp socket counterclockwise one quarter turn. 6. Pull socket from back of lamp. 7. Separate headlamp module from vehicle. INSTALLATION Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a international Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the Driver Airbag Module is depressed. The horn relay is located in the Junction Block. Refer to the Junction Block label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the Junction Block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation > Page 51 Horn Relay: Testing and Inspection Horn Relay Location 1. Remove horn relay from the Junction Block. 2. Using ohmmeter, test between the Junction Block relay terminal 7 and ground for continuity. a. When the horn contact is not depressed, no continuity. b. Continuity to ground when horn contact is depressed. c. If continuity is not correct, repair horn contact or wiring as necessary. 3. Insert a jumper wire between terminals 8 and 10 of the horn relay in the Junction Block. a. If horns sound replace relay. b. If the horns do not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test battery voltage: a. Test Junction Block horn relay terminals 6 and 8 for voltage from fuse 8. b. If not OK, repair as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation > Page 52 Horn Relay: Service and Repair REMOVAL 1. Open driver's door and remove instrument panel end cover. Horn Relay Location 2. Remove horn relay. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations ETACS-ECU ETACS-ECU Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 66 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 71 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 73 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 77 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 78 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 79 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 80 Body Control Module: Connector Views Body 20 Way Connector (At BCM) Engine 14 Way Connector (At BCM) Instrument Panel 10-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 81 Instrument Panel 22-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 82 Body Control Module: Electrical Diagrams Body Control Module Wiring Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 83 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 84 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 85 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information Technician Safety Information WARNING: Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. 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. SERVICING SUB-ASSEMBLIES 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. Only those components with approved Service and Repair procedures in this database should be serviced. DRBIII Scantool Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRB if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. - Do not exceed the limits shown in the table above. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 95 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". 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 because of corrosion. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms Body Control Module: Application and ID Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The terms "gage" and "gauge" are used interchangeably Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms > Page 98 Body Control Module: Application and ID Body Codes Defined JA ............................................................................................................................................................ Chrysler Cirrus, Plymouth Breeze, Dodge Stratus JX ......................................................................... ................................................................................................................... Chrysler Sebring Convertible Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Active Codes: A malfunction that is present now. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 101 ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 102 Body Control Module: Description and Operation Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 103 Body Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 104 Body Control Module: Description and Operation Climate Control Systems A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 105 Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 106 Active Codes: A malfunction that is present now. ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 107 protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Compass Mini-Trip Computer (CMTC) COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located on the right hand side of the instrument cluster. The CMTC is an electronic control module with a Vacuum Fluorescent Display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. Upon ignition the CMTC will turn on all of the segments in the display for 1 second then reverts to the last function screen that was displayed prior to the last ignition cycle. The functions that are available via actuation of the STEP switch are as follows: - Compass and Ambient Temperature - Average Trip Fuel Economy (AVE ECO) - Estimated Range (RANGE) - Present Fuel Economy (ECO) - Trip Odometer (ODO) - Elapsed Ignition On Time (ET) - Blank Screen (off) Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 108 NOTE: The terms "gage" and "gauge" are used interchangeably Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of four gauges, the status of seven indicator lamps, the status and dimming of the PRNDL indicator (VF display), and the dimming of cruise and low fuel lamps to the Mechanical Instrument Cluster (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run," or "start" positions. The PRNDL indicator works when the ignition is in the "off," "run," or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all PRNDL segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the tachometer exceeds 450 rpm. Power Door Lock System POWER DOOR LOCK SYSTEM When the Body Control Module (BCM) receives an input for a lock/unlock request (door lock switch, Remote Keyless Entry (RKE), or door key cylinder switch (w/VTSS only), it will ground the appropriate relay for a specified amount of time. For this vehicle all door lock relays are located inside the body control module and are not serviced separately. The door lock switches provide a variable voltage (Multiplexed (MUX) circuit) to the BCM and the BCM will respond to that command. If the conditions for door lock inhibit exist (key in ignition and left front door open), the BCM will not respond to a lock command. Other power door lock features: Automatic Door Locks This feature can be enabled/disabled by using either the DRB, MDS machine or customer key cycle method. When enabled, all the doors will lock when the vehicle reaches a speed greater than 15 MPH, all doors are closed and an increase of TPS signal is received by the PCM. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the vehicle speed accelerates above 15 MPH. Remote Keyless Entry (RKE) The body control module receives and decodes messages from the remote keyless entry transmitter. The remote keyless entry module is built into the BCM (premium) and is not serviced separately. When the lock button is pressed all doors will lock, horn will chirp, courtesy lamps will turn off and VTSS (if equipped) will arm. When the unlock button is pressed once, the left front door will unlock, courtesy lamps will light (if equipped w/illuminated entry) and VTSS (if equipped) will disarm. If the unlock button is pressed a second time (within 5 seconds of the first), all the other doors will unlock. Panic mode (if equipped with VTSS), is accomplished by pressing both lock and unlock buttons at the same time. 1997 JX transmitters have a separate panic button. This flashes the lights and sounds the horn but does not prevent the engine from running. The BCM will ignore all commands from the transmitter if the vehicle speed is over 15 MPH. This allows the engine to be running during warm up on cold days and then using the RKE to unlock the doors. The RKE software can store up to 4 transmitter codes. Rolling Code (97 JX only) The rolling code features changes part of the key fob (transmitter) message each time it is used. The key fob message and the receiver message increment together. Under certain conditions with a rolling code system (like pressing a button on the fob over 250 times outside of the receiver range) the receiver and transmitter can fall out of synchronization. By pressing specific buttons together, the system will re-synchronize. Radio-CCD RADIO - CCD NOTE: At the present time all 1997 CCD radios are not connected to the CCD bus. The audio systems used in the JX convertible will consist of one of the following radios: RAL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 109 RAL - Base radio with AM/FM stereo, bass and treble sliders only. RBS RBS - AM/FM stereo with cassette tape and CD changer option. Bass and treble controls. This radio may or may not be addressable with DRB. If it is equipped with the Premium Amplifier option (located under the passenger seat), it will be on the CCD bus. The Amplifier will determine whether the CCD connector in the back of the radio is wired. RBR RBR - AM/FM stereo with CD player only. Three band E.Q. Not connected to the bus. Not addressable with DRB. RAZ RAZ - AM/FM stereo with cassette and CD player incorporated into one unit. This system will be equipped with the Premium Amplifier package and will be addressable with the DRB. The amplifier as above is located under the passenger seat. The audio systems available in the JX are made up of the four corporate radios listed above with some additional options with regard to the amplification system. The list breaks down how the separate systems are made up. There are only two of the four radios that will be addressable on the CCD bus with the DRB. The key to knowing which system is addressable is the presence of an amplifier under the passenger seat. This amplifier utilizes a different instrument panel wiring harness that incorporates the CCD connector for the radio. Some of the radios may have a CCD connector in the radio chassis that may not have a connector plugged into it. This is entirely normal if there is no amplifier under the passenger seat. The RBS radio will be available with or without the premium amplifier and therefore will not be addressable via the CCD bus in some packages. When equipped with a Premium Amplifier package, there will be six speakers in the can The amplifier will drive the instrument panel speakers and the door speakers, while the radio will drive the speakers located in the rear quarter panels directly. This means that a "shorted channel" DTC can now be caused by a problem with the wiring or the resistance of the rear quarter panel speakers. In the past, the amplifier (if equipped) drove all the speakers and consequently the circuits from the amplifier to the speakers and the speakers themselves could not be the cause of a shorted channel DTC. 3.8.1 Diagnostics DIAGNOSTICS The RBS radio has several diagnostic messages that may be displayed in the event of a problem with either the radio or the CD changer option. These messages will be displayed on the radio faceplate in the following abbreviated form. The messages are as follows: Display Definition E L-SP LEFT CHANNEL SHORT Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 110 E R-SP RIGHT CHANNEL SHORT E EJCT CANNOT EJECT TAPE E LOAD CANNOT LOAD TAPE E PLAY CANNOT PLAY TAPE The following messages are for the CD changer options; E HOT THE CD CHANGER INTERNAL TEMPERATURE IS TOO HIGH E E-O1 CD CHANGER DEADLOCK (CD JAMMED, CAN'T LOAD OR EJECT) E E-06 CD CHANGER ELEVATOR ERROR E E-07 MAGAZINE EJECT ERROR E EEEE COMMUNICATIONS ERROR (BETWEEN RADIO AND CHANGER) E PLAY CANNOT READ ALL DISCS The left channel short, right channel short and communication error between the radio and CD changer are addressed in the diagnostics. Generally, the rest of the messages will require removal and repair of either the radio or the CD changer. NOTE: When using the diagnostic manual for troubleshooting radio systems, all voltages are D.C. unless otherwise specified. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The Vehicle Theft Security System (VTSS) module is a logic-controlled device (part of the body control module), that monitors vehicle doors, trunk key cylinder, and ignition action for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, courtesy and VTSS lamps, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the cluster will flash fast for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the trunk key cylinder switch is not seen by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. The indicator lamp blinks at a slow rate when the system is armed. For 1997 JX vehicles, once the VTSS is armed the universal garage door opener (if equipped) and the decklid release switch in the center console will be disabled. The decklid release will still operate from the RKE or using the key. When something triggers the alarm, the system will signal for about 18 minutes. For the first three minutes the horn will sound, then the headlamps and courtesy lamps will continue to flash for another 15 minutes. Tamper Alert - If the horn sounds three times when either front door is unlocked, it means the alarm was activated. Check the vehicle for tampering. The VTSS indicator lamp will also flash twice quickly to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by communication between the powertrain control module and the body control module. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 111 System Self-Tests - NOTE: System self-tests can be entered only with the DRB or MDS machine. Upon entering diagnostics, the headlamps, courtesy lamps and VTSS lamp will begin flashing to verify their operation. In addition, the horn will sound twice. Removing the key from the ignition switch will stop the lamps from flashing while keeping the system in diagnostics. While in diagnostics mode, a horn pulse should occur at each of the following events, which indicates proper operation. 1. Beginning with all doors closed, open, then close each door. The horn will sound when the door ajar switch closes, and then again when the switch opens. There must be a one-second delay between closing and opening the switch. 2. Rotate the key in each door lock cylinder to the unlock position. The horn will sound as the switch closes, and again when it opens. There must be a one-second delay between changing switch states, or the horn will not sound. 3. Cycle the key to the ignition RUN position. A single horn pulse will indicate proper operation of the ignition input. This also will take the module out of the diagnostics mode. For any of these tests, if the switch does not remain open or closed for at least one second, the horn will only sound once. The lack of a horn pulse during any operation indicates either: - a switch failure - the lack of that input to the vehicle theft security system module - a failure internal to the module - a faulty horn system Check for continuity at the switch. If this is good, check for an open or shorted wire between the switch and alarm module. Also, check if the Powertrain Control Module (PCM) has been replaced recently. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Vehicle Communication VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate 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 the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver 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 code determines the message that has higher priority, which is then allowed to access the bus first. The two wires 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. 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: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection for diagnostic and repair procedures. Any of the following bus failure messages may be displayed: Short to Battery Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground Either or both of the bus wires are shorted to ground or a specific ground may be open. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 112 Bus (+) & (-) Shorted Together The two bus wires are shorted together. No Termination The bus system has lost connection with all of its terminators. Bus Bias Level Too Low Either or both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High Either or both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias The bus system has lost connection with all modules that provide bias. Bus (+) Open The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open The bus (-) wire has lost connection with termination and/or bias. Not Receiving Bus Messages Correctly The DRB cannot communicate over the bus and does not know why. Wiper System WIPER SYSTEM The front wiper system provides the driver with normal wipe (low and high speeds), intermittent wipe, wiper after wash, and mist wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. Other wiper system features: Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled providing a range of from 1 second to 36 seconds. Mist Wipe When the wiper is in the off position and the driver presses the mist control for more than 125 msec, 1 wipe cycle in low speed mode will be provided. The wipe will continue in low speed as long as the switch is held in that position. Wiper After Wash Mode When the driver presses the wash button for over 3/8 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Body Control Module: Reading and Clearing Diagnostic Trouble Codes Displaying & Reading Trouble Codes CCD Data Link Connector Tip: Reading codes requires the use of a DRBII Diagnostic Readout Box or Equivalent Scan Tool. WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 10 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. NOTE: These diagnostic test procedures have been designed specifically for use with the Chrysler DRBII (Diagnostic Readout Box II). However it should be possible to perform the same tests using an equivalent Scan Tool. NOTE: It is not necessary to perform all of the tests in Diagnostic Charts to diagnose an individual code. Clearing Trouble Codes To clear codes, all codes must be "read," then proceed as follows: 1. After all codes have been read, press ATM. The display will change to the ERASE menu screen. 2. Press "1 ERASE CODES" to erase all codes. The display will return to the airbag menu screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 115 Body Control Module: Component Tests and General Diagnostics Diagnostic Notes - Read First 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. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active code(s). Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. 3.12.1 Active Codes ACTIVE CODES An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. 3.12.2 Stored Codes STORED CODES Airbag codes are automatically stored in the ACM's memory when the ignition is turned off with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 116 If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on," wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Manual A/C (HVAC) - Mode Door Operation MANUAL A/C (HVAC) MODE DOOR OPERATION The DRB trouble codes that indicate a stall failure or a feedback signal failure work together to show what is wrong with the HVAC system. The stall trouble codes mean that the Body Control Module (BCM) cannot force an actuator to the end of the mode door travel. Internal problems in the body control module will set other short-related trouble codes. Having only stall trouble codes indicates that there is a problem with an open or short circuit in the wiring, a bad actuator, a bad mode door or connecting linkage. It is important that the operation of the mode door be checked if an actuator is removed. This can be checked by rotating the door shaft to confirm that the door will stop at both ends of travel. The actuator itself has no stops. It must have the mode door to stop travel to pass the stall test. A feedback signal failure can occur on the mode door. The body control module monitors the feedback signal to check the position of the actuator. The body control module not only checks the level of the signal but also how much the voltage changes. A feedback failure can occur if there is a short or open circuit in the wiring, a bad actuator, a bad body control module, a bad mode door or connecting linkage. The easiest way to diagnose this is to use the DRB to actuate the mode door. Note that the feedback voltage of the actuator should smoothly change as the actuator is moved. A sudden change in the feedback voltage to a 5.0-volt or a 0.0-volt level indicates the actuator is bad. A fixed feedback voltage that is less than 5.0 volts or greater than 0.0 volts without a stall failure, or a short failure indicates that the actuator, the mode door, or a connecting mechanical linkage is jammed preventing movement. A feedback signal voltage that stays on 5.0 volts or 0.0 volts indicates a wiring or body control module problem. The feedback failure trouble code can also occur from a lack of actuator travel. This can be checked by confirming that the feedback signal smoothly changes when the actuator is moved with the DRB. If the signal is ok, the door travel is not correct. The actuator must be removed and the mode door mechanically checked for proper operation. Typical problems that prevent door movement include screws dropped in the A/C unit or warped doors. Replace any part that is found defective. Anytime the voltage to the BCM is interrupted for less than 2 minutes or voltage drops below approximately 10.0 volts (battery disconnected, etc.), it may be necessary to recalibrate the mode door. This can be done by using the DRB, MDS machine or removing the IOD (M1) fuse for 10 seconds, reinstall it and then start the engine. Diagnostic Strategies ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 117 Body Control Module: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRBIII DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform VEHICLE COMMUNICATION TEST 1A. DRBIII Error Messages DRBIII ERROR MESSAGE Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 118 Body Control Module: Service and Repair JUNCTION BLOCK REMOVAL Junction Block/BCM Location The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. Junction Block and Body Control Module assemblies are located on the driver's side of the vehicle. 1. Open the front driver's door and remove end cap. 2. Remove center bezel. 3. Remove instrument cluster hood. 4. Remove silencer. 5. Remove wire harness connectors from Junction Block. 6. Remove Junction Block three mounting screws. 7. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 8. Disconnect BCM wire connectors and remove the assembly. 9. Remove Junction Block/BCM from vehicle. INSTALLATION - For installation, reverse the above procedures. Ensure that the wire terminals and connectors are in good condition and connectors are properly installed. BODY CONTROL MODULE REMOVAL 1. The Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 2. Remove the two BCM attaching screws and release the two BCM locking latches from the Junction Block. 3. Disconnect BCM from the Junction Block. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 119 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII (diagnostic read-out box) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Specifications Powertrain Control Module: Specifications PCM Mounting screw torque ............................................................................................................... .......................................................... 4 Nm (35 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: Component Locations Fig. 16 Power Distribution Center (PDC) The Powertrain Control Module (PCM) is located in the left front engine compartment close to the transmission control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 125 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 128 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 129 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 130 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 131 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 132 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 133 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 134 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 135 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 136 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 137 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 138 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 139 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 140 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 141 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 142 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 143 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 144 Powertrain Control Module: Connector Views Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 145 PCM Connector View Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 146 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. 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 because of corrosion. - 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. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Description and Operation > Component Description Powertrain Control Module: Description and Operation Component Description Fig.9 Power Distribution Center (PDC) The PCM regulates the ignition system. The PCM supplies battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM controls ignition timing by turning on and off a transistor in the distributor. During the crank-start period the PCM maintains spark advance at 9° BTDC. During engine operation the following inputs determine the amount of spark advance provided by the PCM. Intake air temperature. - Coolant temperature. - Engine RPM. - Intake manifold vacuum. The PCM also regulates the fuel injection system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Description and Operation > Component Description > Page 149 Powertrain Control Module: Description and Operation PCM Battery Feed CIRCUIT OPERATION Circuit A14 is used to provide a constant battery feed to the Powertrain Control Module (PCM). This circuit originates in the Power Distribution Center (PDC) and is protected by a 20 Amp fuse located in cavity 5. It is also spliced and provides power for the Automatic Shut Down (ASD) relay, coil and contact sides. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Description and Operation > Component Description > Page 150 Powertrain Control Module: Description and Operation Power (Device) Ground Helpful Information Circuit Z12 which supplies a ground for the PCM high current drivers, terminates at the left strut tower. If the system loses ground for the Z12 circuit the vehicle will not operate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Description and Operation > Component Description > Page 151 Powertrain Control Module: Description and Operation System Operation SYSTEM OPERATION Powertrain Control Module The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. See Charging System/Testing and Inspection/Procedures/On-board Diagnostic System Test. The PCM cannot be repaired and must be replaced if faulty. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Component Tests and General Diagnostics Powertrain Control Module: Component Tests and General Diagnostics Component Testing Testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Diagnostic Charts For Trouble Code charts see Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection SBEC Testing No specific procedures are provided to diagnose the SBEC by itself. Please See: Computers and Control Systems, Testing and Inspection. SBEC failure is determined as a result of a related system failure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Page 154 Powertrain Control Module: Service and Repair Fig. 33 Auxiliary Jumper Terminal POWERTRAIN CONTROL MODULE SERVICE The PCM attaches to a bracket between the air cleaner housing and Power Distribution Center (PDC) Fig. 33. REMOVAL 1. Disconnect negative cable from auxiliary jumper terminal Fig. 33. 2. Disconnect both 40-way connectors from PCM. Fig. 34 PCM Bracket Screws 3. Remove screws attaching PCM to bracket Fig. 34. 4. Lift PCM up to remove it from vehicle. INSTALLATION 1. Install PCM. Tighten mounting screws. 2. Attach both 40-way connectors to PCM. 3. Connect negative cable to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 158 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 159 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 160 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 161 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 162 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, generator field, electronic ignition coil and the heating elements in the oxygen sensors. Refer to Diagrams/Electrical for circuit information. The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. OPERATION The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. When the ignition switch is in On or Start, the PCM momentarily turns on the ASD relay. The PCM also monitors the ASD relay output voltage. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. While the relay is on the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the PDC Fig. 25. The inside top of the PDC cover has label showing relay and fuse identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 163 Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Power for the coil and contact side of the relay is provided by circuit A14. This circuit is HOT at all times and protected by a 20 amp fuse located in cavity 5 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the relay on circuit K51. This circuit connects to cavity 67 of the PCM connector. When the relay is energized, the contacts internal to the relay close connecting circuits A14 and A142. The A142 circuit is spliced and provides power to the fuel injectors, generator, electronic EGR transducer solenoid, and the ignition coil. The A142 circuit is also spliced and connects to the PCM connector, cavity 6. This input is used for ASD sense by the PCM. HELPFUL INFORMATION Check the 20 amp fuse located in cavity 5 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in cavity 5 of the PDC Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 166 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD Relay Test Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 167 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 1 ASD And Fuel Pump Relay Terminals OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Electrical Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 174 Fuel Pump Relay: Diagrams Power Distribution Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 175 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 176 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 177 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 178 Fuel Pump Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) FUEL PUMP RELAY - PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. Power for the solenoid is supplied through a 10A fuse in the Junction Block. The contacts are supplied power through a 20A fuse in the PDC. Refer to Diagrams/Electrical for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. The fuel pump relay is located in the PDC Fig. 25. The inside top of the PDC cover has a label showing relay and fuse location. Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 179 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 180 Fuel Pump Relay: Testing and Inspection Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 184 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 185 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 186 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 187 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 188 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, generator field, electronic ignition coil and the heating elements in the oxygen sensors. Refer to Diagrams/Electrical for circuit information. The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. OPERATION The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. When the ignition switch is in On or Start, the PCM momentarily turns on the ASD relay. The PCM also monitors the ASD relay output voltage. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. While the relay is on the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the PDC Fig. 25. The inside top of the PDC cover has label showing relay and fuse identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 189 Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Power for the coil and contact side of the relay is provided by circuit A14. This circuit is HOT at all times and protected by a 20 amp fuse located in cavity 5 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the relay on circuit K51. This circuit connects to cavity 67 of the PCM connector. When the relay is energized, the contacts internal to the relay close connecting circuits A14 and A142. The A142 circuit is spliced and provides power to the fuel injectors, generator, electronic EGR transducer solenoid, and the ignition coil. The A142 circuit is also spliced and connects to the PCM connector, cavity 6. This input is used for ASD sense by the PCM. HELPFUL INFORMATION Check the 20 amp fuse located in cavity 5 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in cavity 5 of the PDC Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 192 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD Relay Test Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 193 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 1 ASD And Fuel Pump Relay Terminals OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Electrical Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Air Bag Control Module Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 200 * = Wire With Tracer Stripe Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 203 Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 204 Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > General Information Air Bag Control Module: Description and Operation General Information DESCRIPTION The Airbag Control Module (ACM) contains the impact sensor, and a microprocessor that monitors the impact sensor and the airbag system electrical circuits to determine the system readiness. The ACM contains On-Board Diagnostics (OBD), and will send an airbag lamp-on message to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to light the airbag indicator lamp in the instrument cluster when a monitored airbag system fault occurs. OPERATION The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired and, if damaged or faulty, it must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > General Information > Page 207 Air Bag Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Two different circuits supply battery voltage from the junction block to the Airbag Control Module (ACM), they are F14 and F23. The F14 and F23 circuits are connected to separate bus bars internal to the junction block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the junction block bus bars. The F23 circuit supplies battery voltage to the ACM only when the ignition switch is in the RUN position. The F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. A bus bar internal to the ignition switch connects the A1 circuit from the Power Distribution Center (PDC) to the A21 circuit when the switch is in either the START or RUN position. The A21 circuit supplies battery voltage to the junction block bus bar that feeds the F14 circuit. A 20 amp fuse in the PDC, cavity 8, protects the A1 and A21 circuits. A 10 amp fuse in cavity 17 of the unction block protects the F14 circuit. when the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the junction block bus bar that feeds the F23 circuit. A 40 amp fuse in cavity 16 of the PDC protects the A2 and A22 circuits. A 10 amp fuse in cavity 16 of the junction block protects the F23 circuit. The ACM has a case ground and an external dedicated ground, circuit Z2. The dedicated ground connects to the floor pan near the ACM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Page 208 Air Bag Control Module: Service and Repair WARNING: Replace Airbag System components with Chrysler Mopar specified replacement parts. Substitute parts may visually appear interchangeable, but internal differences may result in inferior occupant protection. The ACM contains an impact sensor that enables the system to deploy the air-bags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Raise parking brake lever as high as possible. 3. Loosen set screw on front of shifter knob and remove shift lever knob. 4. Remove plastic plunger rod from shifter lever. 5. Remove lighted PRNDL letter bezel. 6. Remove screws next to floor shifter and in console storage compartment, holding floor console to the brackets on the floor pan. 7. Disconnect wire connector for floor console accessories at floor pan. 8. Separate console from vehicle. 9. Remove the park brake lever assembly. 10. Disconnect wire harness connector from the Airbag Control Module. 11. Remove four module mounting nuts and remove module. CAUTION: Use supplied nuts only. INSTALLATION 1. Install ACM, position ACM (arrow pointing forward) on center tunnel area mounting studs. Attach the two rear mounting nuts and tighten to 14 to 19 N.m (125 to 170 in. lbs.) torque. 2. Position console in vehicle. 3. Verify that the rear locator pin on the bottom of the storage bin is engaged to the slot in the body bracket. 4. Connect the wire connector for the floor console accessories at floor pan. 5. Install lighted PRNDL letter bezel. 6. Install plastic plunger rod to shifter lever. 7. Install shift lever knob and tighten set screw on front of shifter knob. 8. Do not connect battery negative remote cable. Refer to Testing and Inspection/Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 213 Starter Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 214 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 215 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 216 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 217 Starter Relay: Testing and Inspection Starter Relay WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED. Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 223 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 234 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 235 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 241 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 242 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 245 Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 246 Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 247 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 248 Fuse Block PCM Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 249 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 252 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 253 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 254 Part 2 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 255 Part 3 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 256 Part 4 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 257 Part 5 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 258 Part 6 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 259 Part 7 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 260 Part 8 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 261 Part 9 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 262 Part 11 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 265 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 266 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 267 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 268 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 269 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 270 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 271 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 272 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 273 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 274 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 275 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 276 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 277 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, 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 over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 278 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 281 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 285 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 286 Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection Heated Glass Element Relay: Testing and Inspection 1. Check fuses. a. Fuse 15 in the Junction Block b. Fuse 8 and 12 in the Power Distribution Center. Rear Window Defogger Relay (EBL) 2. Remove the rear window defogger relay EBL. from the Junction Block. 3. Using voltmeter, test battery voltage: a. Test rear window defogger relay terminals 11 for battery voltage. If voltage is OK, go to Step 2. If voltage is not OK, repair A4 circuit. b. Test rear window defogger relay terminals 15 for battery voltage. If voltage is OK, go to Step 3. If voltage is not OK, repair circuit between terminal 15 and fuse 15 in the Junction Block. c. Use a known good relay. If not OK, repair circuits as necessary. If OK, replace relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Page 291 Heated Glass Element Relay: Service and Repair REMOVAL 1. Open the driver's door and remove instrument panel end cover. Rear Window Defogger Relay (EBL) 2. Remove rear window defogger relay from the Junction Block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 296 Wiper Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 297 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 298 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 299 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Description and Operation Arm/Disarm Switch: Description and Operation CIRCUIT OPERATION There are two switches used to ARM and DISARM the system. They are located in the left front and right front doors. These switches use resistors internal to the switch to send a signal to the Body Control Module (BCM) on the operators request. Power for the switches is supplied on circuit M1. This circuit is the Ignition-Off-Draw (IOD) circuit and is protected by a 10 amp fuse located in cavity 5 of the junction block. When the operator has selected the ARM or DISARM function voltage is supplied on circuit M1 through the CLOSED contacts in the switch, through the appropriate resistor, to the BCM. Circuit C73 is used as an input to the BCM for the left door switch, and circuit G72 is used for the right door switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION The Vehicle Theft Security System (VTSS) uses the door ajar switches to provide an input to the Body Control Module (BCM). These switches are normally OPEN with the doors CLOSED. When a door is opened the switch CLOSES completing a path to ground. Circuit G74 is used to monitor the right front, right rear, and the left rear door. The G75 circuit is used for the left front door. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 308 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Remove door trim and water shield. VTSS Door Lock Switch Location 2. Remove illuminated entry switch wiring clip and disconnect connector. 3. Remove disarming switch from door handle. INSTALLATION - For installation reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Left Door Key Cylinder Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Left Door Key Cylinder Switch Connector > Page 314 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION The trunk key cylinder switch is located on the trunk latch and is used as an input to the Body Control Module (BCM) when the key cylinder is being tampered with. This switch is normally CLOSED. Power for the switch is supplied on circuit G71 from the BCM. Ground for the switch is supplied on the Z1 circuit. When the key cylinder is being tampered with the switch OPENS and the path to ground is lost. The BCM then operates the alarm. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 318 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The VTSS trunk lock switch is part of the trunk latch. For replacement, the trunk latch will need to be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door Lock Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door Lock Switch Connector > Page 324 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 325 Power Door Lock Switch: Description and Operation CIRCUIT OPERATION The door lock switches use resistors internal to the switch. There are different resistors used for the LOCK and UNLOCK functions. Both switches have the same amount of resistance for the LOCK and UNLOCK functions. When the operator selects the LOCK or UNLOCK function, from either switch, voltage is passed through the CLOSED contacts in the switch, through the appropriate resistor, to the P96 circuit for the right front door, and circuit P97 for the left front door. These circuits then connect to the Body Control Module (BCM). The BCM then process this request and supplies power and ground to the appropriate circuits. When the LOCK function is selected power is supplied on circuit P33 to all the motors. Ground is supplied on circuit P34. For the UNLOCK function the circuits are reversed. On vehicles without Vehicle Theft Security System (VTSS) all door motors are spliced together. When the vehicle is equipped with VTSS the LEFT FRONT door motor uses a separate circuit for the UNLOCK function. Circuit P55 is used to control the this function and operates the same as the P34 circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 326 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity Test Remove the switch from its mounting location. Using an ohmmeter, test door lock switch continuity and move the switch to the Lock and Unlock positions. If the resistance values are not obtained, replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 327 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Disconnect switch wire connector. 3. Remove switch attaching screws and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and a left position. Moving the switch to either of these positions changes the voltage path internal to the switch (changes polarity at the motors). When the switch is moved to the LEFT position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected, the power and ground are reversed. If a LEFT door mirror movement LEFT is selected, voltage is supplied- through the P95 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected, the power and ground are reversed. When the switch is moved to the RIGHT position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected, the power and ground are reversed. If a RIGHT door mirror movement LEFT is selected, voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected, the power and ground are reversed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 331 Power Mirror Switch: Testing and Inspection 1. Remove door trim panel. 2. Disconnect wire connector. Mirror Switch Test 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test. 4. If test results are not obtained as shown, replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 332 Power Mirror Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Disconnect wire connector. 3. Remove attaching screws. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch: Testing and Inspection 1. Remove switch from mounting position. Power Seat Switch 2. Using an ohmmeter, perform the Switch Continuity Tests below and refer for Pin locations. if there is no continuity at any of the switch positions, replace switch. Switch Continuity Test Switch Position = Between Continuity Off = B-N, B-J, B-M, B-E, B-K, B-L Vertical Up = B-M, B-E, A-N, A-J Vertical Down = B-N, B-J, A-M, A-E Horizontal AFT = B-K, A-L Horizontal Forward = B-L, S-K Front Tilt Up = S-J, B-E Front Tilt Down = A-E, B-J Rear Tilt Up = A-N, B-N Voltage The following test will determine whether or not voltage is continuous through the body harness to the switch. 1. Remove power seat switch from mounting position and disconnect switch from wiring harness. 2. Connect one lead of test light to Pin B of the ground terminal, and touch other test light lead to Pin A. 3. If test light comes on, harness to switch is good. if test light does not come on, perform circuit breaker test. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 336 Power Seat Switch: Service and Repair REMOVAL 1. Remove lower recliner handle. 2. Remove screws holding seat side shield to seat frame. 3. Disconnect wiring from switch. 4. Remove screws attaching switch to seat side shield. 5. Remove switch. INSTALLATION - For installation, reverse the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations Master Cylinder Fluid Level Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 341 Brake Fluid Level Switch: Service and Repair GENERAL INFORMATION The master cylinder or brake fluid reservoir does not have to be removed from vehicle for replacement of the brake fluid level sensor. Master Cylinder Fluid Level Sensor 1. Remove wiring harness connector from brake fluid reservoir level sensor. Brake Fluid Level Switch Retaining Tabs 2. Compress retaining tabs on end of brake fluid level switch. Removing/Installing Fluid Reservoir Level Switch 3. While compressing retaining tabs, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Correctly align the replacement level switch with its mounting hole in the brake fluid reservoir. Push switch into fluid reservoir until retaining tabs are fully expanded on opposite side of fluid reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 342 5. Install the wiring harness connector onto the brake fluid level switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 353 39 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 354 43 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 355 45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 356 47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 357 51 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 358 55 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 359 57 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 360 59 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 361 63 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 362 67 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 363 69 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 364 71 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 365 173 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 366 177 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 367 179 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 368 181 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 369 187 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 370 191 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 371 193 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 372 195 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 373 201 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 374 205 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 375 207 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 376 209 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 377 256 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 378 Wheel Speed Sensor: Specifications Front Rear Clearance Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in Runout 0.006 in 0.006 in Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 379 Wheel Speed Sensor: Service Precautions NOTE: - Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. CAUTION: - If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. - When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 380 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor PURPOSE One Wheel Speed Sensor (WSS) is located at each wheel, and sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a Toothed Sensor Ring (Tone Wheel) passes the stationary magnetic WSS. The CAB converts the AC signal generated at each wheel into a digital signal. OPERATION If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. ASSEMBLY AND LOCATION The front Wheel Speed Sensor is attached to a boss in the steering knuckle. The tone wheel is part of the outboard constant velocity joint. The rear Wheel Speed Sensor on rear drum brake applications is mounted to the rear brake support plate and the rear tone wheel is an integral part of the rear wheel hub and bearing assembly. SERVICE INDIVIDUALLY The four Wheel Speed Sensors are serviced individually. The front Tone Wheels are serviced as an assembly with the outboard constant velocity joint. The rear Tone Wheels are serviced as an assembly with the rear hub and bearing assembly. CORRECT OPERATION DEPENDENT ON ACCURATE SIGNALS Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 381 Wheel Speed Sensor: Testing and Inspection CAREFUL INSPECTION Carefully inspect tone wheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tone wheels should show no evidence of contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive Runout - of the tonewheel can cause erratic wheel speed sensor signals. Refer to Tone-wheel Runout under Specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect For Looseness - on their mounting surfaces. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. See: Specifications Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Removal PROCEDURE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Speed Sensor Cable Routing Brackets 3. Remove the speed sensor cable routing bracket from the steering knuckle. Remove the wiring harness sealing grommet retainer and speed sensor routing bracket from the inner fender. Wheel Speed Sensor Connection To Vehicle Wiring Harness 4. Remove speed sensor sealing grommet from the inner fender. Then unplug the speed sensor cable from the vehicle wiring harness. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 384 Speed Sensor Head Attachment To Steering Knuckle 5. Remove bolt attaching the speed sensor head to the steering knuckle. Then remove speed sensor head from steering knuckle. CAUTION: If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. Speed Sensor Head Removal From Steering Knuckle 6. If speed sensor head can not be removed from steering knuckle by hand, the locating pin on the speed sensor head has seized to the steering knuckle do to corrosion. Remove speed sensor head from steering knuckle using the following procedure. Remove disc brake caliper from steering knuckle, and remove brake rotor from hub/bearing assembly Then insert a pin punch through hole in front steering knuckle and tap speed sensor head locating pin out of steering knuckle. Installation PROCEDURE CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cable, resulting in an open circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 385 Wheel Speed Sensor Connection To Vehicle Wiring Harness 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. Speed Sensor Cable Routing Brackets 2. Install the speed sensor cable assembly grommet into the front inner fender. Install speed sensor cable grommet retainer/routing bracket on the inner fender of the vehicle and install and securely tighten attaching bolt. Correct Front Wheel Speed Sensor Cable Routing CAUTION: When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. 3. Install the speed sensor cable routing bracket on the steering knuckle. Install and tighten routing bracket mounting bolt to a torque of 12 Nm (105 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 386 Installing Speed Sensor Head In Steering Knuckle 4. Install speed sensor head on steering knuckle. When installing speed sensor head on steering knuckle, apply a small amount of grease on speed sensor locating pinch Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pinch Install the speed sensor head attaching screw and tighten to a torque of 6 Nm (55 inch lbs.). 5. Install the wheel and tire assembly on vehicle. 6. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 387 Wheel Speed Sensor: Service and Repair Rear Removal PROCEDURE Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 1. Unplug the speed sensor cable connector from the vehicle wiring harness. Access for speed sensor cable to vehicle wiring harness connection is in the trunk of the vehicle. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove the rear tire and wheel assembly from the vehicle. Rear Speed Sensor Cable Attachment To Body 4. Remove speed sensor cable sealing grommet retainer from the rear frame rail of the vehicle. Then remove speed sensor cable sealing grommet and cable from hole in body of vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 388 Speed Sensor Cable Attachment To Rear Suspension 5. Remove speed sensor routing clips from the rear upper control arm and brake flex hose routing bracket. Rear Speed Sensor Head Attachment To Brake Support Plate 6. Remove the rear speed sensor head from the rear brake support plate. Installation PROCEDURE CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. Rear Speed Sensor Head Attachment To Brake Support Plate 1. Install speed sensor head into brake support plate. 2. Install wheel speed sensor attaching bolt. Tighten the speed sensor head attaching bolt to 8 Nm (75 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 389 Speed Sensor Cable Attachment To Rear Suspension 3. Install speed sensor cable routing clips on the brake flex hose bracket and the bracket on the upper control arm. Install and securely tighten the routing clip attaching bolts. 4. Install connector end of speed sensor cable through hole in inner fender and into trunk of vehicle. Rear Speed Sensor Cable Attachment To Body 5. Install speed control sealing grommet into hole in inner fender. Install the sealing grommet retainer and attaching bolt on rear frame rail. Securely tighten retainer attaching bolt. 6. Install the tire and wheel assembly on vehicle. 7. Lower vehicle. Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 8. Plug speed sensor cable connector into vehicle wiring harness. Install foam sleeve back over the speed sensor cable to vehicle wiring harness connection to prevent connector from rattling against body of vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 390 9. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant temperature sensor torque ..................................................................................................... .......................................................... 27 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 396 Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor And Oil Pressure Switch Locations Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 397 Engine Coolant Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 398 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor is installed in the housing between the filler neck and thermostat Fig. 7. The sensor provides an input voltage to the PCM. The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emissions and improve driveability - Because spark advance changes at different engine operating temperatures during warm-up, all spark advance testing should be done with the engine fully warmed. The PCM demands slightly richer air-fuel mixtures and higher idle speeds until the engine reaches normal operating temperature. The engine coolant sensor input is also used for radiator fan control. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. This sensor input is also used for the instrument cluster coolant temperature gauge. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 4 Engine Coolant Temperature Sensor 1. With key off, disconnect wire connector from engine coolant temperature sensor Fig. 4. 2. Connect one lead of ohmmeter to one terminal of engine coolant temperature sensor. 3. Connect the other lead of ohmmeter to remaining terminal of engine coolant temperature sensor. The ohmmeter should read as follows; - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F, ohmmeter should read approximately 7,000 to 13,000 ohms. 4. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between connector terminal 43 and the sensor harness connector. Refer to Wiring Diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 401 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 402 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. REMOVAL 1. Drain cooling system until coolant level is below engine coolant temperature sensor. Refer to Cooling System. 2. Disconnect electrical connector from sensor. 3. Remove sensor from engine. INSTALLATION 1. Install ECT sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME/ACCELERATE, SET/COAST and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. when speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the COAST/SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the RES/ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. It, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the RES/ ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the RAM when the RES/ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the RES/ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the SET/COAST switch until the desired speed is reached. Then release the switch. The ON and OFF switches operates two components: the PCM's ON/OFF input, and the battery voltage to the brake switch, which powers the speed control servo. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 407 Cruise Control Switch: Testing and Inspection Speed Control Switch 1. Remove the ON/OFF and CANCEL speed control switch assembly and disconnect the two-way connector. 2. Using an ohmmeter, touch a lead to each pin. The meter should read 22,848 to 22,351 ohms. Press the CANCEL button, the ohmmeter should read 0 to 0.5 ohms. Press the ON/OFF button, the ohmmeter should read 668 to 653 ohms. If the resistance does not fall within these values replace the switch. 3. Remove the SET/RESUME speed control switch assembly and disconnect the two-way connector. 4. Using an ohmmeter, touch a lead to each pin. The meter should read no continuity Press the SET button, the ohmmeter should read 1,978 to 2,022 ohms. Press the RESUME button, the ohmmeter should read 5,558 to 5,682 ohms. If the resistance do not fall within these values replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 408 Cruise Control Switch: Service and Repair Speed Control Switch The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS . REMOVAL 1. Turn off ignition. 2. Remove two screws from side of each switch. 3. Rock switch away from airbag and steering wheel. 4. Disconnect two-way electrical connector. 5. Repeat for the other switch. INSTALLATION For installation reverse above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 417 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 423 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > Vehicle Speed Sensor Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair Vehicle Speed Sensor VEHICLE SPEED SENSOR 1. Raise vehicle on hoist. 2. Remove wiring connector from speed sensor. CAUTION: Clean area around speed sensor before removing. This will prevent the possibility of dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt. 4. Remove speed sensor from transaxle. CAUTION: Carefully remove vehicle speed sensor so that sensor drive gear does not fall into transaxle. Should sensor drive gear fall into the transaxle during sensor removal, drive gear must be reattached to sensor. To install, reverse removal procedure. Confirm vehicle speedometer is functioning properly following installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > Vehicle Speed Sensor > Page 426 Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair Vehicle Speed Sensor Drive Gear VEHICLE SPEED SENSOR DRIVE GEAR 1. Raise vehicle on hoist. 2. Remove wiring connector from speed sensor. CAUTION: Clean area around speed sensor before removing. This will prevent the possibility of dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt. 4. Remove speed sensor from transaxle. CAUTION: Carefully remove vehicle speed sensor so that sensor drive gear does not fall into transaxle. Should sensor drive gear fall into the transaxle during sensor removal, drive gear must be reattached to sensor. 5. Remove speed sensor drive gear from speed sensor. To install, reverse removal procedure. Confirm vehicle speedometer is functioning properly following installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Circuit Information Evaporator Probe: Description and Operation Circuit Information CIRCUIT OPERATION A/C Evaporator Temperature Sensor The A/C evaporator temperature sensor, located in the A/C-Heater housing, provides the Body Control Module (BCM) with the evaporator temperature to prevent the evaporator from freezing. Power for the sensor is provided from the BCM to the sensor on circuit C12. The ground for the sensor is on circuit C57 to the BCM. Information on evaporator temperature is sent to the Powertrain Control Module (PCM) across the CCD Bus. The PCM uses this information to control operation of the A/C compressor clutch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Circuit Information > Page 437 Evaporator Probe: Description and Operation Evaporator Temperature Sensor EVAPORATOR PROBE The evaporator temperature probe prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow It does this by cycling the compressor clutch on and off. The switch is attached to the evaporator coil with the sensing probe inserted into the coil fins. The evaporator probe is a temperature sensing element located at the coldest point on the face of the evaporator. Output from the probe is sampled by the Body Control Module (BCM). It is used to switch the A/C compressor clutch OFF before evaporator freeze up occurs. The clutch is switched OFF when the probe temperature reaches O.94°C. (33.7°F.). It is allowed to switch ON when the probe temperature reaches 2.05°C. (35.7°F). The evaporator probe is located on the lower right side of the evaporator housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Page 438 Evaporator Probe: Service and Repair Fig 41 Evaporator Probe Wiring REMOVAL 1. Disconnect battery. 2. Remove right under panel silencer/duct. 3. Disconnect wiring connector for evaporator probe. Fig 42 Evaporator Probe 4. Using a flat blade pry tool pull back on the locking tab. Twist the access plate clockwise one quarter turn and remove plate. Fig 43 Remove Probe 5. Pull probe out of evaporator core. This plate must be pushed inside the A/C unit and orientated in such a way that the plate can be removed. INSTALLATION 1. Install new probe into the evaporator. The new probe must not go into the same hole (in the evaporator core) that the old probe was removed. The evaporator is manufactured with three holes for probe insertion. Insert the probe in the uppermost hole. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Page 439 2. Install evaporator probe access panel. 3. Connect probe wiring harness. 4. Reconnect battery. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Fig 12 Pressure Transducer The pressure transducer is screwed attached to a valve on the discharge line near the compressor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 443 Refrigerant Pressure Sensor / Switch: Description and Operation Fig 11 Pressure Transducer - Viewed From Beneath Vehicle Fig 12 Pressure Transducer The A/C Pressure Transducer functions as the refrigerant system pressure sensor. It supports the condenser/radiator fans and compressor functions. The pressure transducer is attached to a valve on the discharge line near the compressor. Circuit C18 connects from the Powertrain Control Module (PCM), cavity 42, to the transducer. The PCM uses information from the transducer to control operation of the radiator fans. Ground for the transducer is supplied on circuit K4. This circuit connects to cavity 43 of the PCM connector. The K4 circuit is spliced in with many of the sensors used in the fuel injection and ignition systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 444 Refrigerant Pressure Sensor / Switch: Service and Repair Fig 12 Pressure Transducer CAUTION: A/C pressure transducer switch connector terminal contacts can be damaged by probing tools during system diagnosis and repair. Failure to use their respective mating terminals or pin gauge to check for tightness will cause contact beam spreads. This will result in loss of continuity. NOTE: O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for this vehicle. REMOVAL 1. Disconnect the wire harness connector from the A/C pressure transducer. NOTE: A slight release of pressure trapped in the fitting may be experienced. It is not necessary to discharge the refrigerant system. 2. Remove the transducer with a counterclockwise rotation using a 14 mm open-end wrench. INSTALLATION For installation, reverse above procedures. Tighten pressure transducer to 6 Nm (50 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation CIRCUIT OPERATION The dimmer control is used to control the intensity of the instrument panel lamps. It is located in the left multi-function switch. Power for the control is supplied from the L7 circuit, which is the feed for the parking lamps. This circuit is HOT when the parking lamp switch is in the ON position. Ground for the control is provided on the Z1 circuit which terminates at the instrument panel left side cowl. The control uses a variable resistor and is connected to circuit E19. Circuit E19 connects to the Body Control Module (BCM). When the operator moves the control, resistance in the circuit changes and the signal sent to the BCM changes. With the change is resistance the BCM sends a signal over the CCD Bus to the instrument panel changing the lamp intensity. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications SENDING UNIT RESISTANCE -- OHMS Full (142.2 ± 4.0 mm) Nominal ............................................................................................................................................... ............................................................... 70 - Upper Limit ........................................................................................................................................ ................................................................ 90 - Lower Limit ........................................................................................................................................ ............................................................... 50 3/4 Tank (97.2 mm) Nominal ............................................................................................................................................... ............................................................. 340 - Upper Limit ........................................................................................................................................ .............................................................. 370 - Lower Limit ........................................................................................................................................ ............................................................. 310 1/2 Tank (66.1 mm) Nominal ............................................................................................................................................... ............................................................. 550 - Upper Limit ........................................................................................................................................ .............................................................. 580 - Lower Limit ........................................................................................................................................ ............................................................. 520 1/4 Tank (34.8 mm) Nominal ............................................................................................................................................... ............................................................. 760 - Upper Limit ........................................................................................................................................ .............................................................. 790 - Lower Limit ........................................................................................................................................ ............................................................. 730 Empty (0.5 ± 4.0 mm) Nominal ............................................................................................................................................... ........................................................... 1050 - Upper Limit ........................................................................................................................................ ............................................................ 1080 - Lower Limit ........................................................................................................................................ ........................................................... 1020 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 452 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions Stop Lamp Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 460 Stop Lamp Switch: Description and Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mounted Stop Lamp CHMSL, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 461 Stop Lamp Switch: Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Lighting and Horns/Brake Light Switch/Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 462 Stop Lamp Switch: Adjustments Stop Light Switch Location In Vehicle PROCEDURE 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 463 Stop Lamp Switch: Service and Repair Stop Light Switch Location In Vehicle REMOVE 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALL NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in step Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > 10 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > 10 Way Connector > Page 468 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Multi-Function Switch 1. Remove multi-function switch. Multi-Function Switch Continuity Test 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the following continuity charts. The switch assembly is mounted center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 472 Hazard Warning Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering and Suspension/Steering/steering column cover removal procedures. Multi-Function Switch 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION For installation, reverse the above procedures. 1. Tighten multi-function switch to column retaining screws to 2.3 N.m (20 in. lbs.) torque. 2. Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > 7 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > 7 Way Connector > Page 477 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > 10 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > 10 Way Connector > Page 482 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection The horn contact consist of: - A contact switch is mounted between the Driver Airbag Module and steering wheel - The horn wire is attached to Driver Airbag Module mounting bracket. - When the Driver Airbag Module is pressed the contact ring touches the bracket mounting bolts and makes contact to ground. The ground signal is carried to the horn relay and horn sounds. Horn Contact 1. Ground horn wire. 2. If does not horn sounds check for corrosion on wire, bracket or airbag contact ring and ensure horn wire is properly connected. 3. If bracket needs to be replaced, the steering wheel must be replaced. If contact ring is bad the Driver Airbag Module must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection > Page 486 Horn Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM REMOVAL OR INSTALLATION PROCEDURES, REMOVE AND ISOLATE THE BATTERY NEGATIVE CABLE FROM THE VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable in engine compartment. 2. Remove the screws that attach the Driver Airbag Module to the steering wheel. 3. Lift the module to gain access and disconnect the squib wire. 4. Place Driver Airbag Module on a clean level surface with pad facing upward. 5. If the contact area is bad, replace Driver Airbag Module. If the mounting bracket or bushings are bad, replace steering wheel. INSTALLATION - For installation, reverse the above procedures. Use caution not to pinch wires. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > 7 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > 7 Way Connector > Page 491 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 492 Turn Signal Switch: Testing and Inspection Multi-Function Switch 1. Remove multi-function switch. Multi-Function Switch Continuity Test 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the following continuity charts. The switch assembly is mounted center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 493 Turn Signal Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering and Suspension/Steering/steering column cover removal procedures. Multi-Function Switch 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION For installation, reverse the above procedures. 1. Tighten multi-function switch to column retaining screws to 2.3 N.m (20 in. lbs.) torque. 2. Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions > Page 499 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located on the rear side of the front bumper beam. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the Powertrain Management/Computers and Control Systems/Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: 1. Disconnect the sensor from the engine harness. 2. Attach ohmmeter leads to the wire terminals of the sensor. 3. At room temperature of 25 °C (75 - 80°F), an ohmmeter reading of 9 K to 11 K ohms should be observed. 4. If reading is above or below the specification, replace the sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 502 Battery Temperature Sensor: Service and Repair REMOVAL 1. Raise vehicle on host. 2. Remove screw from sensor. 3. Disconnect electrical connector from sensor. INSTALLATION 1. Connect electrical connector to sensor. 2. Install screw and tighten. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) Camshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 506 Camshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 507 Camshaft Position Sensor: Description and Operation Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. OPERATION This vehicle is equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. The distributor is also equipped with an internal camshaft position (fuel sync) sensor Fig. 2. This sensor provides fuel injection synchronization and cylinder identification to the PCM. The camshaft position sensor contains a hall effect device called a sync signal generator. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the shutter enters the sync signal generator, the interruption of magnetic field causes the voltage to switch high. This causes a sync signal of approximately 5 volts. When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts. Since the shutter rotates at half crankshaft speed, it may take one engine revolution during cranking for the PCM to determine the position of piston number 6. NO CAM SIGNAL AT PCM FAULT MESSAGE Purpose The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. Operation The sensor is provided with 12 volts from the fused ignition switch output circuit and the powertrain control module supplies a sensor ground. The CMP sensor has a 5 volt pull-up from the PCM. The sensor signal is created when the distributor's pulse ring is rotated past the camshaft position sensor. When Monitored: The crankshaft position sensor signal trouble code is not set. With the ignition in either the start or run position and battery voltage between 4 and 15 volts. Set Condition: Too many crankshaft position sensor signals detected without any camshaft position sensor signal Possible Causes: Open fused ignition switch output circuit (12V) - Open sensor ground - Damaged pulse ring - Failed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 508 - Failed PCM - Inoperative distributor drive - Broken timing belt - Connector terminals - Connector wires Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 511 Camshaft Position Sensor: Service and Repair The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant temperature sensor torque ..................................................................................................... .......................................................... 27 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 515 Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor And Oil Pressure Switch Locations Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 516 Engine Coolant Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 517 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor is installed in the housing between the filler neck and thermostat Fig. 7. The sensor provides an input voltage to the PCM. The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emissions and improve driveability - Because spark advance changes at different engine operating temperatures during warm-up, all spark advance testing should be done with the engine fully warmed. The PCM demands slightly richer air-fuel mixtures and higher idle speeds until the engine reaches normal operating temperature. The engine coolant sensor input is also used for radiator fan control. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. This sensor input is also used for the instrument cluster coolant temperature gauge. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 4 Engine Coolant Temperature Sensor 1. With key off, disconnect wire connector from engine coolant temperature sensor Fig. 4. 2. Connect one lead of ohmmeter to one terminal of engine coolant temperature sensor. 3. Connect the other lead of ohmmeter to remaining terminal of engine coolant temperature sensor. The ohmmeter should read as follows; - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F, ohmmeter should read approximately 7,000 to 13,000 ohms. 4. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between connector terminal 43 and the sensor harness connector. Refer to Wiring Diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Component Testing > Page 520 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Page 521 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. REMOVAL 1. Drain cooling system until coolant level is below engine coolant temperature sensor. Refer to Cooling System. 2. Disconnect electrical connector from sensor. 3. Remove sensor from engine. INSTALLATION 1. Install ECT sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor screw torque ................................................................................................................................................... 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 525 Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 526 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 527 Crankshaft Position Sensor: Description and Operation Fig. 5 Timing Slots Fig. 3 Crankshaft Position Sensor--Adjustable Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 528 Fig 12 Crankshaft Position Sensor Location -- Typical OPERATION The crankshaft position sensor Fig. 3 detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots Fig. 5. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. - The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. - It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The sensor connector has a Christmas tree attached to the heater tube bracket. - The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On automatic transmission vehicles this circuit is spliced and provides an input to the Transmission Control Module (TCM). The PCM provides a ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. HELPFUL INFORMATION The K7 circuit supplies 8 volts to the distributor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 9 Crankshaft Position Sensor REMOVAL 1. Remove speed control servo from driver's side strut tower. 2. Remove crankshaft position sensor retaining bolt Fig. 9. 3. Pull crankshaft position sensor straight up out of the transaxle housing. 4. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. INSTALLATION - ADJUSTABLE Some vehicles may be equipped with an adjustable crankshaft position sensor. This can be identified by an elongated mounting hole in the sensor. Fig. 10 Crankshaft Position Sensor And Spacer If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor Fig. 10. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 2. Connect crankshaft position sensor electrical connector to the wiring harness connector. 3. Attach connector to heater tube bracket. 4. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. INSTALLATION - NON-ADJUSTABLE 1. Install sensor in transaxle. 2. Install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. 4. Attach connector to heater tube bracket. 5. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 533 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel level input comes across the CCD bus from the body control module. this input is used for the Fuel System and Misfire Monitors. If the fuel level is below approximately 1/16th of a tank the Fuel System and Misfire monitors will be disabled. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake air temperature sensor torque ....................................................................................................................................................... 11.5 Nm (100 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 540 Fig. 21 Intake Air Temperature Sensor And MAP Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 541 Intake Air Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 542 Intake Air Temperature Sensor: Description and Operation Fig. 11 Intake Air Temperature Sensor And MAP Sensor PURPOSE The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. OPERATION The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. - At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to cavity 37 of the PCM connector. The IAT sensor threads into the intake manifold Fig. 11. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. The K21 circuit connects to cavity 37 of the PCM connector. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground path for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Component Testing Intake Air Temperature Sensor: Testing and Inspection Component Testing Fig. 5 Intake Air Temperature Sensor And MAP Sensor NOTE: To perform a complete test of this sensor and its circuit, SEE System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from the intake air temperature sensor Fig. 5. 2. Connect a high input impedance (digital) volt-ohmmeter to the sensor terminals. The ohmmeter should read as follows: - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 37 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. Refer to Electrical Diagrams for circuit information. - If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 545 Intake Air Temperature Sensor: Service and Repair Fig. 21 Intake Air Temperature Sensor And MAP Sensor The intake air temperature sensor threads into the intake manifold plenum Fig. 21. REMOVAL 1. Remove electrical connector from sensor. 2. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Electrical Specifications > Page 550 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP sensor torque .............................................................................................................................. ....................................................... 3.4 Nm (30 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 551 Fig. 21 Intake Air Temperature Sensor And MAP Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 552 Map Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 553 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 5 Intake Air Temperature Sensor And MAP Sensor OPERATION The MAP sensor reacts to absolute pressure in the intake manifold and provides an input voltage to the PCM. The PCM interprets the MAP sensor input as engine load. The input voltage level supplies the PCM with information relating to ambient barometric pressure during engine start-up (cranking) and engine load while its operating. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. The PCM supplies 5 volts direct current to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. At key on, before the engine is started, the PCM determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The sensor is mounted on the intake manifold Fig. 1. The sensor is connected to the throttle body or intake manifold with a vacuum hose and to the PCM electrically CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Manifold Absolute Pressure (MAP) sensor Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides a ground path for the MAP signal (circuit K1) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 30 MAP Sensor Connector NOTE: Complete testing of this component and its circuit is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 3 (Fig. 30). - With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. - The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. - If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (+/0.5V). Five volts (+/-0.5V) should also be at terminal 43 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. NOTE: Complete testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 556 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 volts to the A/C pressure switch and the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Throttle position sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 557 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 21 Intake Air Temperature Sensor And MAP Sensor The MAP sensor attaches to the intake manifold plenum Fig. 21. REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seal. 2. Tighten mounting screws to 3.4 Nm (30 in. lbs.) torque. 3. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle Technical Service Bulletin # 18-01-98 Date: 980116 MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle NO: 18-01-98 GROUP: Driveability DATE: Jan. 16, 1998 SUBJECT: MIL Illumination with Hex Code $3E, Possible Sags/Hesitations/Rough Idle MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: MIL illumination with hex code $3E - UPSTREAM O2 SENSOR SHORTED TO VOLTAGE along with possible symptoms of sags/hesitation or rough idle. NOTE: HEX CODE $3E MUST BE SEEN TO PERFORM THIS REPAIR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-94-TF-91 0.4 Hrs. FAILURE CODE: P8 - New Part 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 DTC $3E is present, follow the diagnostic procedure in the applicable diagnostic manual. If no apparent reason is found for the DTC, perform the Repair Procedure. Parts/Equipment Required 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable AR (1) 05010885AA Kit, Oxygen Sensor Jumper (4-cyl & 96/97 6-cyl) AR (1) 05010934AA Kit, Oxygen Sensor Jumper (1995 6-cyl) AR 04778570 Heat Shrink Tubing AR (1) 04778138 Tape, Cloth Underhood Electrical 1 NPN Soldering Iron 1 NPN Rosin Core Solder Repair Procedures This bulletin involves cutting and splicing a jumper from the oxygen sensor(s) to the powertrain control module. Single Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector and disconnect it. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 566 3. Identify the sensor ground terminal. For 1997 models it is terminal No. 3, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). For 1995/1996 models it is terminal No. 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1997 connectors use a rear secondary lock latch at the rear side of the connector. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 3 by carefully pulling from the rear while spreading the two locking fingers. 1995/1996 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal No. 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out from the rear. 5. Choose the terminal on the end of the repair lead p/n 05010885AA that matches the removed terminal. Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. NOTE: THE TERMINAL END ON THE OPPOSITE END OF THE NEW LEAD IS FOR THE OTHER APPLICABLE YEAR VEHICLES. THIS TERMINAL MUST BE CLIPPED OFF. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 567 8. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 9. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 10. Cut the k4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 11. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. 12. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 13. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 14. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 15. Reconnect the battery negative cable. 16. Verify the wiring repair by running the oxygen sensor test with the DRB III. Double Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector # 1 and disconnect it. 3. Identify the sensor ground terminal. For 1995 models, it is terminal # 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1995 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal # 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out form the rear. 5. Choose the terminal on the end of the repair lead p/n 05010934AA that has the longer length of wire from the Y splice (1100 mm). Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Repeat steps 3 through 6 for the upstream oxygen sensor No. 2, using the other lead from the Y spliced repair jumper. 8. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. 9. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 10. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 11. Cut the K4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 568 13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 14. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 15. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 16. Reconnect the battery negative cable. 17. Verify the wiring repair by running the oxygen sensor test with the DRB III. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle Technical Service Bulletin # 18-01-98 Date: 980116 MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle NO: 18-01-98 GROUP: Driveability DATE: Jan. 16, 1998 SUBJECT: MIL Illumination with Hex Code $3E, Possible Sags/Hesitations/Rough Idle MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: MIL illumination with hex code $3E - UPSTREAM O2 SENSOR SHORTED TO VOLTAGE along with possible symptoms of sags/hesitation or rough idle. NOTE: HEX CODE $3E MUST BE SEEN TO PERFORM THIS REPAIR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-94-TF-91 0.4 Hrs. FAILURE CODE: P8 - New Part 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 DTC $3E is present, follow the diagnostic procedure in the applicable diagnostic manual. If no apparent reason is found for the DTC, perform the Repair Procedure. Parts/Equipment Required 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable AR (1) 05010885AA Kit, Oxygen Sensor Jumper (4-cyl & 96/97 6-cyl) AR (1) 05010934AA Kit, Oxygen Sensor Jumper (1995 6-cyl) AR 04778570 Heat Shrink Tubing AR (1) 04778138 Tape, Cloth Underhood Electrical 1 NPN Soldering Iron 1 NPN Rosin Core Solder Repair Procedures This bulletin involves cutting and splicing a jumper from the oxygen sensor(s) to the powertrain control module. Single Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector and disconnect it. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 574 3. Identify the sensor ground terminal. For 1997 models it is terminal No. 3, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). For 1995/1996 models it is terminal No. 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1997 connectors use a rear secondary lock latch at the rear side of the connector. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 3 by carefully pulling from the rear while spreading the two locking fingers. 1995/1996 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal No. 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out from the rear. 5. Choose the terminal on the end of the repair lead p/n 05010885AA that matches the removed terminal. Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. NOTE: THE TERMINAL END ON THE OPPOSITE END OF THE NEW LEAD IS FOR THE OTHER APPLICABLE YEAR VEHICLES. THIS TERMINAL MUST BE CLIPPED OFF. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 575 8. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 9. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 10. Cut the k4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 11. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. 12. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 13. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 14. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 15. Reconnect the battery negative cable. 16. Verify the wiring repair by running the oxygen sensor test with the DRB III. Double Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector # 1 and disconnect it. 3. Identify the sensor ground terminal. For 1995 models, it is terminal # 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1995 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal # 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out form the rear. 5. Choose the terminal on the end of the repair lead p/n 05010934AA that has the longer length of wire from the Y splice (1100 mm). Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Repeat steps 3 through 6 for the upstream oxygen sensor No. 2, using the other lead from the Y spliced repair jumper. 8. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. 9. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 10. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 11. Cut the K4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 576 13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 14. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 15. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 16. Reconnect the battery negative cable. 17. Verify the wiring repair by running the oxygen sensor test with the DRB III. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 577 Oxygen Sensor: Specifications - After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. - If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite (R) 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. - Tighten the sensor to 28 Nm (20 ft. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 580 Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 581 Fig 12 Upstream Heated Oxygen Sensor 1/1 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Front Upstream Oxygen Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor > Page 584 Downstream Oxygen Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 585 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 586 Oxygen Sensor: Description and Operation Fig 12 Upstream Heated Oxygen Sensor 1/1 OPERATION As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic converter, one downstream of the converter. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop. the PCM adjusts injector pulse width based on preprogrammed (fixed values and inputs from other sensors. The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 12). Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 587 DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 13). The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. CIRCUIT OPERATION Circuit A14 is connected to the BUS bar in the Power Distribution Center (PDC), which connects to battery voltage. The contact side of the Automatic Shut-Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse, located in cavity 5 of the PDC, protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM. The A142 circuit also splices to cavity 6 of the PCM connector. The input by circuit A142 tells the PCM that the ASD relay is energized. The A142 circuit supplies voltage for the upstream heated oxygen sensor and circuit F142 supplies voltage to the downstream heated oxygen sensor. The F142 circuit is protected by a 10 Amp fuse located in cavity 1 of the PDC. Power for the fuse is supplied by circuit A142. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the downstream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream (left) and downstream (right) heated oxygen sensor signals (circuits K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Circuit Z1 provides the ground path for the heater circuits in the sensors. This ground terminates at the right frame rail. Circuit K4 splices to supply ground for the signals for the following: Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Vehicle speed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, distributor, ASD relay, generator, and the EGR solenoid. The PCM controls the ground path for each of the components powered by circuit A142. Circuit K4 splices to supply ground for the signals for the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Vehicle speed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 590 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 5 and 7 ohms. NOTE: This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. NOTE: Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS ONLY (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 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 connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See, sensor heating element test. 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. NOTE: Complete testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 591 Oxygen Sensor: Service and Repair Fig 89 Upstream Oxygen Sensor REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector from sensor. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 89). INSTALLATION 1. After removing the sensor the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. - If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. - Tighten the sensor to 28 Nm (20 ft lb) torque. 2. Connect electrical connector to sensor. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 592 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revision NUMBER: 26-10-96 GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus, Stratus & Breeze - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs 8W-80-44 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 597 8W-80-45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 598 8W-80-46 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 599 8W-80-47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 602 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 603 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 604 Power Steering Pressure Switch: Description and Operation Fig. 21 Power Steering Pressure Switch PURPOSE On some vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. OPERATION The pressure switch improves vehicle idle quality, by maintaining required engine idle speed when necessary, do to increased pressure in the power steering system. This increased pressure will slow down the power steering pump which will decrease engine idle speed. The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear on vehicle's requiring its usage. When power steering pump pressure exceeds 4137 kPa (600 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z1 provides a ground for the power steering pressure switch. The ground is terminated at the left strut tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 605 Power Steering Pressure Switch: Service and Repair REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on the back side of the power steering gear. 4. Remove the vehicle's wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Output Voltage At idle ................................................................................................................................................... ...................................... greater than 0.6 volts At wide open throttle (WOT) ........................................................................................................................................................... less than 4.5 volts Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 610 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 611 Fig. 23 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 612 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 613 Throttle Position Sensor: Description and Operation Fig. 23 Throttle Position Sensor PURPOSE Along with inputs from other sensors, the PCM uses TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the PCM) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to a maximum of 3.7 volts at wide open throttle. The throttle position sensor mounts to the side of the throttle body Fig. 23. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides a ground path for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 Volts to the A/C pressure switch and the map sensor. On automatic transmission vehicles, circuit K22 is spliced and provides an input to the Transmission Control Module (TCM). Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 616 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be greater than 0.6 volts. - At wide open throttle, TPS output voltage should be less than 4.5 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 617 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 618 Throttle Position Sensor: Service and Repair Fig. 37 Throttle Position Sensor The TPS attaches to the side of the throttle body Fig. 37. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and TPS. 3. Remove throttle body. 4. Remove TPS mounting screws. 5. Remove throttle position sensor. Fig. 38 Indexing Throttle Position Sensor INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 38. - The socket has two tabs inside it. The throttle shaft rests against the tabs. - When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. - The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. - Tighten mounting screws to 2 Nm (17 in. lbs.) torque. NOTE: After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 2. Install throttle body to intake manifold. 3. Attach electrical connectors to idle air control motor and throttle position sensor. 4. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 627 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 628 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 629 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 635 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 636 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 641 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 642 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 643 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 649 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 650 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 651 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 654 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 655 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 656 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 657 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 658 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 664 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 665 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 666 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 667 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 668 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 669 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 670 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 671 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 672 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 673 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 674 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 675 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 676 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 677 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 678 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 679 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 680 Vehicle Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 681 Vehicle Speed Sensor: Description and Operation TRANSMISSION CONTROL MODULE -- AUTO TRANS -- PCM INPUT The Transmission Control Module (TCM) supplies 3 inputs to the PCM: Vehicle Speed (road speed) - Torque Management - Gear Position VEHICLE SPEED The TCM supplies vehicle speed and distance traveled inputs to the PCM. From these inputs and the throttle position sensor input, the PCM determines when a deceleration condition occurs. TORQUE MANAGEMENT The PCM receives a torque management input from the TCM. The PCM receives the input when the transmission shifts gears. In response, the PCM shuts off a number of fuel injectors when the transmission shifts gears. Fig. 24 Vehicle Speed Sensor--Manual Transmission VEHICLE SPEED SENSOR - PCM INPUT (MANUAL TRANSMISSION) The vehicle speed sensor is located in the transmission extension housing Fig. 24. The sensor input is used by the PCM to determine vehicle speed and distance traveled, manual transmission only. Refer to Transmission Control Module for automatic transmission. The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate the following functions or systems: Speedometer - Speed Control - Daytime Running Lights (Canadian Vehicles Only) - Open Throttle IAC position. CIRCUIT OPERATION On vehicles equipped with the manual transmission, a Vehicle Speed Sensor (VSS) located in the transmission is used. Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the VSS. The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7, from the VSS, provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides a ground path for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 is spliced and provides an input to the Body Control Module (BCM) for vehicle speed. Circuit K4 splices to supply ground for the signals for the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 684 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 100). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor. 2. Install mounting bolt. 3. Connect electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Output Voltage At idle ................................................................................................................................................... ...................................... greater than 0.6 volts At wide open throttle (WOT) ........................................................................................................................................................... less than 4.5 volts Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 690 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 691 Fig. 23 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 692 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 693 Throttle Position Sensor: Description and Operation Fig. 23 Throttle Position Sensor PURPOSE Along with inputs from other sensors, the PCM uses TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the PCM) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to a maximum of 3.7 volts at wide open throttle. The throttle position sensor mounts to the side of the throttle body Fig. 23. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides a ground path for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 Volts to the A/C pressure switch and the map sensor. On automatic transmission vehicles, circuit K22 is spliced and provides an input to the Transmission Control Module (TCM). Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 696 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be greater than 0.6 volts. - At wide open throttle, TPS output voltage should be less than 4.5 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 697 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 698 Throttle Position Sensor: Service and Repair Fig. 37 Throttle Position Sensor The TPS attaches to the side of the throttle body Fig. 37. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and TPS. 3. Remove throttle body. 4. Remove TPS mounting screws. 5. Remove throttle position sensor. Fig. 38 Indexing Throttle Position Sensor INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 38. - The socket has two tabs inside it. The throttle shaft rests against the tabs. - When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. - The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. - Tighten mounting screws to 2 Nm (17 in. lbs.) torque. NOTE: After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 2. Install throttle body to intake manifold. 3. Attach electrical connectors to idle air control motor and throttle position sensor. 4. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) Camshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 703 Camshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 704 Camshaft Position Sensor: Description and Operation Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. OPERATION This vehicle is equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. The distributor is also equipped with an internal camshaft position (fuel sync) sensor Fig. 2. This sensor provides fuel injection synchronization and cylinder identification to the PCM. The camshaft position sensor contains a hall effect device called a sync signal generator. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the shutter enters the sync signal generator, the interruption of magnetic field causes the voltage to switch high. This causes a sync signal of approximately 5 volts. When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts. Since the shutter rotates at half crankshaft speed, it may take one engine revolution during cranking for the PCM to determine the position of piston number 6. NO CAM SIGNAL AT PCM FAULT MESSAGE Purpose The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. Operation The sensor is provided with 12 volts from the fused ignition switch output circuit and the powertrain control module supplies a sensor ground. The CMP sensor has a 5 volt pull-up from the PCM. The sensor signal is created when the distributor's pulse ring is rotated past the camshaft position sensor. When Monitored: The crankshaft position sensor signal trouble code is not set. With the ignition in either the start or run position and battery voltage between 4 and 15 volts. Set Condition: Too many crankshaft position sensor signals detected without any camshaft position sensor signal Possible Causes: Open fused ignition switch output circuit (12V) - Open sensor ground - Damaged pulse ring - Failed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 705 - Failed PCM - Inoperative distributor drive - Broken timing belt - Connector terminals - Connector wires Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 708 Camshaft Position Sensor: Service and Repair The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor screw torque ................................................................................................................................................... 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 712 Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 713 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 714 Crankshaft Position Sensor: Description and Operation Fig. 5 Timing Slots Fig. 3 Crankshaft Position Sensor--Adjustable Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 715 Fig 12 Crankshaft Position Sensor Location -- Typical OPERATION The crankshaft position sensor Fig. 3 detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots Fig. 5. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. - The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. - It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The sensor connector has a Christmas tree attached to the heater tube bracket. - The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On automatic transmission vehicles this circuit is spliced and provides an input to the Transmission Control Module (TCM). The PCM provides a ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. HELPFUL INFORMATION The K7 circuit supplies 8 volts to the distributor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 9 Crankshaft Position Sensor REMOVAL 1. Remove speed control servo from driver's side strut tower. 2. Remove crankshaft position sensor retaining bolt Fig. 9. 3. Pull crankshaft position sensor straight up out of the transaxle housing. 4. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. INSTALLATION - ADJUSTABLE Some vehicles may be equipped with an adjustable crankshaft position sensor. This can be identified by an elongated mounting hole in the sensor. Fig. 10 Crankshaft Position Sensor And Spacer If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor Fig. 10. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 2. Connect crankshaft position sensor electrical connector to the wiring harness connector. 3. Attach connector to heater tube bracket. 4. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. INSTALLATION - NON-ADJUSTABLE 1. Install sensor in transaxle. 2. Install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. 4. Attach connector to heater tube bracket. 5. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 720 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 730 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 731 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 732 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 733 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 734 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 735 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 736 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 737 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 738 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 739 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 740 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 741 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 747 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 748 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 749 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 750 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 751 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 752 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 753 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 754 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 755 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 756 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 757 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 758 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 759 Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 760 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start Lock Cylinder Retaining Tab REMOVAL 1. Disconnect negative cable from auxillary jumper terminal -- on driver's side strut tower. 3. Remove upper steering column shroud. 3. Pull lower shroud down far enough to access lock cylinder retaining tab. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to RUN position (retaining tab on lock cylinder can be depressed). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 761 Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the RUN position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the OFF position. Remove the key. 5. Install steering column shrouds. 5. Connect negative cable to auxillary battery terminal on shock tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 767 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 768 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 769 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 770 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 771 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 772 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 773 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (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 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (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. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 774 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 775 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 776 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 777 PARTS REQUIRED: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 778 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 on T.I.L. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 779 POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations NOTE: The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 785 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 786 Impact Sensor: Description and Operation CIRCUIT OPERATION The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service Precautions > Page 791 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located on the rear side of the front bumper beam. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the Powertrain Management/Computers and Control Systems/Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: 1. Disconnect the sensor from the engine harness. 2. Attach ohmmeter leads to the wire terminals of the sensor. 3. At room temperature of 25 °C (75 - 80°F), an ohmmeter reading of 9 K to 11 K ohms should be observed. 4. If reading is above or below the specification, replace the sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 794 Battery Temperature Sensor: Service and Repair REMOVAL 1. Raise vehicle on host. 2. Remove screw from sensor. 3. Disconnect electrical connector from sensor. INSTALLATION 1. Connect electrical connector to sensor. 2. Install screw and tighten. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 804 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 805 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 806 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 807 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 808 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 809 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 810 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 811 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 812 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 813 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 814 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 815 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 821 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 822 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 823 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 824 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 825 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 826 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 827 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 828 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 829 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 830 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 831 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 832 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 833 Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 834 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start Lock Cylinder Retaining Tab REMOVAL 1. Disconnect negative cable from auxillary jumper terminal -- on driver's side strut tower. 3. Remove upper steering column shroud. 3. Pull lower shroud down far enough to access lock cylinder retaining tab. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to RUN position (retaining tab on lock cylinder can be depressed). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 835 Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the RUN position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the OFF position. Remove the key. 5. Install steering column shrouds. 5. Connect negative cable to auxillary battery terminal on shock tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revision NUMBER: 26-10-96 GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus, Stratus & Breeze - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs 8W-80-44 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 842 8W-80-45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 843 8W-80-46 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 844 8W-80-47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 847 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 848 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 849 Power Steering Pressure Switch: Description and Operation Fig. 21 Power Steering Pressure Switch PURPOSE On some vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. OPERATION The pressure switch improves vehicle idle quality, by maintaining required engine idle speed when necessary, do to increased pressure in the power steering system. This increased pressure will slow down the power steering pump which will decrease engine idle speed. The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear on vehicle's requiring its usage. When power steering pump pressure exceeds 4137 kPa (600 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z1 provides a ground for the power steering pressure switch. The ground is terminated at the left strut tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 850 Power Steering Pressure Switch: Service and Repair REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on the back side of the power steering gear. 4. Remove the vehicle's wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Autostick Switch Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 856 Autostick Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 865 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 866 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 867 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 873 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 874 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 879 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 880 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 881 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 887 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 888 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 889 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 892 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 893 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 894 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 895 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 896 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 905 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 910 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 911 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 912 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 918 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 923 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 924 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 925 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 926 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 927 Input / Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 930 Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 931 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Master Window Switch Passenger Window Switch Continuity Test For switch testing, remove the switch from its mounting. Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 939 Power Window Switch: Service and Repair REMOVAL Master Switch 1. Remove driver's door trim panel. 2. Remove three mounting screws. 3. Remove switch and disconnect wire connector. Passenger Switch 1. Remove passenger door trim panel. 2. Disconnect switch wire connector. 3. Remove switch from bezel. INSTALLATION Master Switch and Passenger Switch For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 944 Windshield Washer Switch: Testing and Inspection Windshield Washer Diagnosis Whenever a windshield washer malfunction occurs, first verify that the windshield washer wire harness is properly connected to all connectors before starting normal diagnosis and repair procedures. Refer to Windshield Washer Diagnosis Chart. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 948 Wiper Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering and Suspension/Steering/steering column cover removal procedures. Multi-Function Switch Mounting 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION For installation, reverse the above procedures. 1. Tighten multi-function switch to column retaining screws to 2.3 N.m (20 in. lbs.) torque. 2. Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications FRONT WHEEL ALIGNMENT: Camber: Acceptable Range ................................................................................................................ ...................................................................... -0.6 to to +0.6° Preferred Setting .................................. .............................................................................................................................................................. .......... 0.0° Toe Right/Left: Acceptable Range ....................................................................................................... ................................................................... +0.05° out to +0.15° in Preferred Setting ........................ .............................................................................................................................................................. ............ +0.05° in Total Toe: [1] Acceptable Range ......................................................................................................... ..................................................................... +0.1° out to +0.3° in Preferred Setting .......................... .............................................................................................................................................................. ............ +0.1° in Caster:* Acceptable Range ................................................................................................................. ........................................................................ +2.3 to +4.3° Preferred Setting ................................... .............................................................................................................................................................. ....... +3.3° *Side To Side Caster Difference Not To Exceed: Acceptable Range ................................................. ......................................................................................................................................... +1.0° or less Preferred Setting .......................................................................................................................... ................................................................................ 0.0° REAR WHEEL ALIGNMENT: Camber: Acceptable Range ................................................................................................................ ...................................................................... -0.6 to to +0.2° Preferred Setting .................................. .............................................................................................................................................................. ......... -0.2° Toe Right/Left: Acceptable Range ....................................................................................................... ................................................................... +0.05° out to +0.15° in Preferred Setting ........................ .............................................................................................................................................................. ............ +0.05° in Total Toe: [2] Acceptable Range ......................................................................................................... ..................................................................... +0.1° out to +0.3° in Preferred Setting .......................... .............................................................................................................................................................. ............ +0.1° in Thrust Angle: Acceptable Range ......................................................................................................... ......................................................................... -0.15 to to +0.15° Preferred Setting ........................... .............................................................................................................................................................. ................. 0.0° [1] Total toe is the arithmetic sum of the left and right wheel toe settings. Positive is Toe-in, negative is Toe-out. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Left and right toe must be equal to within 0.02 degrees. [2] Toe Out: When backed on Alignment Rack is Toe In when driving. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Information Alignment: Description and Operation General Information Proper vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspension angles. These angles are what affects the handling and steering of the vehicle when it is in motion. The method of checking a vehicle's front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used. Instructions furnished by the manufacturer of the equipment being used should always be followed to ensure accuracy of the alignment, except alignment specifications recommended by Chrysler Corporation MUST ALWAYS be used. CAUTION: Do not attempt to modify any suspension or steering components by heating or bending of the component. Wheel alignment adjustments should always be made in the following sequence, to ensure that an accurate alignment is performed. 1. Adjust rear camber to be at the preferred setting specification. 2. Adjust rear wheel Toe to be at the preferred setting specification.. 3. Adjust front wheel Toe to be at the preferred setting specification for individual wheel Toe and for total Toe. 4. Toe is measured in degrees or inches and is the distance that the front edges of the tires are closer (or farther apart) than the rear edges. 5. Thrust Angle is defined as the average of the Toe settings on each rear wheel. If this measurement is out of specification, re-adjust rear wheel Toe so that each wheel has 1/2 of the total Toe measurement. When re-adjusting, do not exceed the total Toe specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Information > Page 955 Alignment: Description and Operation Caster/Camber Description On this vehicle, the front suspension caster and camber settings and the rear suspension caster settings, are determined at the time the vehicle is designed. This is accomplished by very accurately locating the vehicle's suspension components when designing and assembling the vehicle. This is called a Net Build: vehicle and results in no required or available adjustment of front and rear caster and front camber after the vehicle is built or when servicing the suspension components. Thus Caster and Camber are not normally considered an adjustable specification when performing an alignment on this vehicle. Though Caster and Camber are not adjustable they must be checked to ensure they meet vehicle specifications. If a vehicle's front camber is found to be outside of the required specifications, the vehicles front suspension components should be inspected for any signs of damage or bending. Rear Camber on this vehicle is adjustable. The rear camber on this vehicle is adjusted using the adjusting screw located in the forward and rear lateral links of the vehicles rear suspension. Rear Caster on this vehicle is not adjustable and is not shown as an alignment specification. CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating, bending or any other modification of the suspension components. NOTE: When checking the rear alignment on this vehicle the alignment rack must be equipped with rear skid plates. Correctly position vehicle on alignment rack and install all required equipment on vehicle, per the alignment equipment manufacturers specifications. NOTE: Prior to reading each alignment specification, front and rear of vehicle should be jounced an equal number of times. Induce jounce-(rear first then front) by grasping center of bumper and jouncing each end of vehicle an equal number of times. Bumper should always be released when vehicle is at the bottom of the jounce cycle. Correctly jounce vehicle and read front and rear alignment settings and compare to vehicle specifications for camber, caster and toe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 956 Alignment: Testing and Inspection Before any attempt is made to change or correct the wheel alignment factors. The following part inspection and the necessary corrections should be made to those parts, which influence the steering of the vehicle. 1. Check and inflate all tires to recommended pressure. All tires should be the same size and in good condition and have approximately the same wear. Note the type of tread wear which will aid in diagnosing. 2. Check front wheel and tire assembly for radial runout. 3. Inspect lower ball joints and all steering linkage for looseness. 4. Check for broken or sagged front and rear springs. 5. Check vehicle ride height to verify it is within specifications. 6. Alignment MUST only be checked after the vehicle has the following areas inspected and or adjusted. Recommended tire pressures, full tank of fuel, no passenger or luggage compartment load and is on a level floor or a properly calibrated alignment rack. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 957 Alignment: Service and Repair FRONT WHEEL TOE AND REAR WHEEL TOE AND CAMBER SETTING PROCEDURE 1. Prepare vehicle as described in the-Pre-Alignment Vehicle Inspection procedure. 2. Center steering wheel and lock in place using a steering wheel clamp. NOTE: When performing the Front Toe and Rear Camber and Toe setting procedure, the rear wheel Camber and Toe MUST be set to the preferred specification first, then set front wheel Toe to the preferred specification. CAUTION: Do not attempt to straighten or repair a lateral link. Do not apply heat to the lateral link adjusting screws or to the jam nuts, when loosening or adjusting the lateral links. 3. Loosen the adjusting screw jam nuts on all 4 of the rear lateral arm adjusting screws. CAUTIONS: Do not attempt to move the adjusting screws without properly loosening the jam nuts. Note that each adjusting screw has one right-handed nut and one left-handed nut. - When setting rear Camber and Toe on the vehicle, the maximum lengths of the adjustable lateral link at the locations shown must not be exceeded. If these maximum lengths are exceeded, inadequate retention of adjustment link to the inner and outer link may result. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 958 4. Rough in Rear Camber setting as close as possible to the preferred specification first, by mainly adjusting the rear lateral link adjusting screw. Some adjustment of the forward lateral link adjusting screw will also be required to get Rear Camber setting to preferred specification. 5. Adjust the forward lateral link adjusting screw to set rear Toe to preferred specification. - Adjusting Toe will cause a slight change in the Camber setting. If during setting of Toe, Camber no longer is at the preferred specification, continue to adjust Camber and Toe until both are at their preferred specifications. 6. While holding adjustment screws from turning, use a crow foot and torque wrench, and tighten all lateral link adjusting screw jam nuts to a torque of 65 Nm (48 ft. lbs.). This will securely hold adjusting screws from turning. CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. 7. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate inner tie rods of steering gear to set front Toe to the preferred Toe specification. 8. Tighten tie rod locknuts to 61 Nm (45 ft. lbs.) torque. 9. Adjust steering gear to tie rod boots at inner tie rod. 10. Remove steering wheel clamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Adapter Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 miles ................................................................................ .............................................................................................. 450 - 1,100 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 500 - 1,100 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 967 Idle Speed: Testing and Inspection Fig. 35 Purge Hose 1. Turn ignition key to Off. 2. Disconnect the PCV valve hose from the intake manifold nipple. Cap the PCV vacuum nipple. 3. Disconnect purge hose from the nipple on the throttle body Fig. 35. Fig. 37 Orifice6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) to the purge nipple on the throttle body Fig. 37. 5. Ensure that all accessories are off. 6. Connect the DRB Scan Tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB Scan Tool, access Minimum Airflow Idle Speed. 9. The following will then occur: - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB Scan Tool displays engine RPM 10. If idle RPM is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. - Below 1,000 miles ............................................................................................................................. ........................................... 450 - 1,100 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 500 - 1,100 rpm 11. If idle RPM is above specifications, use the DRB Scan Tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves. DO NOT let Mopar (TM) Parts Cleaner come in contact with eyes or skin. DO NOT ingest the cleaner. Wash thoroughly after using cleaner. a. Remove the throttle body from engine. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar (TM) Parts Cleaner. Only use Mopar (TM) Parts Cleaner to clean the throttle body. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 968 c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB Scan Tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Housing And Element REMOVAL 1. Unfasten clasps on rear of air cleaner housing cover. Lift cover off air cleaner housing. Air Cleaner Housing And Element 2. Remove filter element. 3. If necessary clean the inside of the air cleaner housing. INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps in place. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 977 Fuel Pressure Release: Service and Repair Fig. 2 Releasing Fuel Pressure Fig. 1 Fuel Pressure Test Port--Typical CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock. 1. Disconnect the fuel rail electrical harness from the engine harness. Refer to Diagrams/Electrical. 2. Connect one end of a jumper wire to the A142 circuit terminal of the fuel rail harness connector. 3. Connect the other end of the jumper wire to a 12 volt power source. 4. Connect one end of a jumper wire to a good ground source. 5. Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector. Repeat procedure for 2 to 3 injectors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Fig. 1 Spark Plug Cable Routing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Fig. 1 Spark Plug Cable Routing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 560 Ohms per Inch 3,000 Ohms per Foot 6,700 Ohms per Foot Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 988 Ignition Cable: Description and Operation Spark Plug cables are sometimes referred to as secondary ignition wires. They transfer electrical current from the distributor, to individual spark plugs at each cylinder. They transfer electrical current from the distributor to individual spark plugs at each cylinder. The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Check the spark plug cable connections for good contact at the coil and distributor cap towers and at the spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil and distributor cap towers and spark plug cover should fit tight around spark plug insulators. - Loose cable connections can cause ignition malfunctions by permitting water to enter the towers, corroding, and increasing resistance. 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. Clean high tension cables with a cloth moistened with a non-flammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 991 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from cable clips. 3. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. 4. Connect the ohmmeter between the spark plug end terminal and the corresponding electrode inside the cap. - Make sure ohmmeter probes are 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 the same manner. To test the connection between the coil and distributor terminals: 1. Remove distributor cap. 2. Connect an ohmmeter between center contact in the cap and coil tower terminal. - Resistance should be approximately 5,000 ohms. - If resistance is not within tolerance, replace the cap. - If no problems are found, refer to Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 560 Ohms per Inch 3,000 Ohms per Foot 6,700 Ohms per Foot Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, 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. WARNING: The ignition system generates approximately 32,000 volts. Personal injury could result from contact with this system. 2. With the 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. - Replace cracked, leaking or faulty cables. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 992 Ignition Cable: Service and Repair Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 1 Spark Plug Cable Routing Remove the distributor cap and inspect the inside for: flash over - cracking of carbon button - lack of spring tension on carbon button - cracking of cap - burned, worn terminals - Also check for broken distributor cap towers. If any of these conditions are present the distributor cap and/or cables should be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection > Page 997 Distributor Cap: Service and Repair Fig. 1 Spark Plug Cable Routing When replacing the distributor cap, transfer cables from the original cap to the new cap one at a time. Ensure each cable is installed into the corresponding tower of the new cap. Fully seat the wires into the towers. If necessary refer to the appropriate engine firing order diagram Fig. 1. Light scaling of the terminals can be cleaned with a sharp knife. If the terminals are heavily scaled, replace the distributor cap. A cap that is greasy, dirty or has a powder-like substance on the inside should be cleaned with a solution of warm water and a mild detergent. Scrub the cap with a soft brush. Thoroughly rinse the cap and dry it with a clean soft cloth. Fig. 11 Distributor Cap Screws REMOVAL & INSTALLATION 1. Remove bolt holding air inlet resonator to intake manifold. 2. Loosen clamps holding air cleaner cover to air cleaner housing. 3. Remove PCV make-up air hose from air inlet tube. 4. Loosen hose clamp at throttle body. 5. Remove air inlet tube, resonator and air cleaner cover. 6. Remove EGR tube. 7. Remove spark plug cables from distributor cap. 8. Loosen distributor cap holddown screws and remove cap Fig. 11. 9. Transfer cables from old cap to new cap. The cap is numbered and so are the cables. 10. Install distributor cap. 11. Install distributor holddown washers and nuts. Tighten nuts to 13 Nm (9 ft lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Replace the rotor if: it is cracked - the tip is excessively burned or heavily scaled - the spring terminal does not have adequate tension Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection > Page 1001 Ignition Rotor: Service and Repair Fig. 11 Distributor Cap Screws Fig. 13 Distributor Rotor Button And Spring REMOVAL 1. Remove bolt holding air inlet resonator to intake manifold. 2. Loosen clamps holding air cleaner cover to air cleaner housing. 3. Remove PCV make-up air hose from air inlet tube. 4. Loosen hose clamp at throttle body. 5. Remove air inlet tube, resonator and air cleaner cover. 6. Remove EGR tube. 7. Remove spark plug cables from distributor cap. 8. Loosen distributor cap holddown screws and remove cap Fig. 11. 9. Mark the rotor position and remove rotor. The mark indicates where to position the rotor when reinstalling the distributor. 10. Inspect rotor for cracks or burned electrode. If any of these conditions exist, replace rotor. 11. Inspect rotor button for damage. Replace button and spring as required. Pull button and spring out of cap Fig. 13. 12. Reverse the removal steps for installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .............................. 0.965-1.092 mm (0.038-0.043 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1005 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................. RC10PYP4 Thread size .................................................... ................................................................................................................................................. (14 mm) 3/4 in. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1006 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 1,000 ohm tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Remove the spark plugs and examine them for burned electrodes and 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 recommended intervals. Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. This engine uses platinum spark plugs. CAUTION: Do not attempt to adjust the gap of a platinum plug. Cleaning of the platinum plug may damage the platinum tip. If carbon deposits must be removed, use a plug cleaner and complete cleaning within 20 seconds to protect electrode. Do not use a wire brush. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1009 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1010 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1011 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1012 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. 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 COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1013 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. 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 .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1014 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1015 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection NOTE: 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. - 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 -- SEE Spark Plug Condition. 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 0.038 - 0.043 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1016 Spark Plug Overheating Overheating is indicated by a 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. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1017 Spark Plug: Adjustments Fig 2 Platinum Pads Setting Spark Plug Electrode Gap CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge Fig. 3. - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. - Gap 0.038 to 0.043 in Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1018 Spark Plug: Service and Repair Fig. 3 Intake Manifold Sensors And Left Plenum Support SPARK PLUG SERVICE When replacing the spark plug and coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Do not attempt to adjust the gap of a platinum plug. Cleaning of the platinum plug may damage the platinum tip. If carbon deposits must be removed, use a plug cleaner and complete cleaning within 20 seconds to protect electrode. Do not use a wire brush. SPARK PLUG REMOVAL Remove the spark plugs and examine them for burned electrodes and 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. SPARK PLUG REMOVAL - #2, #4 OR #6 Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1/2 turn and pulling straight back in a steady motion. 1. Prior to removing the spark plug spray compressed air around the spark plug hole and the area around the spark plug. 2. Remove the spark plug using a quality socket with a rubber or foam insert. 3. Inspect the spark plug condition. SPARK PLUG REMOVAL - #1, #3 OR #5 1. Disconnect negative cable from auxiliary jumper terminal. 2. Unplug connectors from MAP and intake air temperature sensors Fig. 3. 3. Remove plenum support bracket bolt located rearward of MAP sensor Fig. 3. 4. Remove bolt holding air inlet resonator to intake plenum Fig. 4. Fig. 4 Air Inlet Resonator 5. Loosen throttle body air inlet hose clamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1019 6. Release snaps holding air cleaner housing cover to housing. 7. Remove air cleaner cover and inlet hoses from engine. 8. Unplug TPS and idle air control motor connectors Figs. 5 and 6. 9. Pry retainer tab back on throttle cable and slide cable out of bracket Fig. 7. Remove cable from throttle lever. 10. Slide Speed control cable out of bracket, if equipped Fig. 7. Remove cable from throttle lever. 11. Remove EGR tube from intake plenum Fig. 8. Fig. 5 Throttle Sensor Position Sensor Fig. 6 Idle Air Control Module Fig. 7 Throttle Cable Attachment 12. Remove plenum support bracket bolt located rearward of EGR tube Fig. 8. 13. Remove bolts holding upper intake plenum and remove plenum. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1020 Fig. 8 EGR Tube And Right Manifold Support Bolt 14. Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1/2 turn and pulling straight back in a steady motion. 15. Prior to removing the spark plug spray compressed air around the spark plug hole and the area around the spark plug. 16. Remove the spark plug using a quality socket with a rubber or foam insert. 17. Inspect the spark plug condition. Fig 2 Platinum Pads SPARK PLUG INSTALLATION CAUTIONS: - Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. - Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. - Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicles original spark plugs that have been determined good. Do not apply anti-seize compound to new spark plugs. - Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the anti- seize compound doesn't make contact with the spark plug electrodes or ceramic insulator. - Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without following the correct procedures. - Always tighten spark plugs to the specified torque Over tightening can cause distortion resulting in a change in the spark plug gap. Over tightening can also damage the cylinder head. Tighten spark plugs to 28 Nm (20 ft. lbs.) torque. - Due to the engine packaging environment for these engines. extreme care should be used when installing the spark plugs to avoid cross threading problems. 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install ignition cables over spark plugs. 4. Install new gasket and position upper intake plenum. Tighten plenum bolts to 18 Nm (13 ft lb) torque. 5. Install bolts at plenum support brackets. Tighten bolts to 18 Nm (13 ft lb). 6. Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 in lb). 7. Install throttle and speed control (if equipped) cables. 8. Attach electrical connectors to sensors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1021 9. Tighten air inlet tube clamps to 2-4 Nm (20-30 in lb) torque. 10. Connect negative terminal to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION PRESSURE (at 250 - 400 RPM): Standard .............................................................................................................................................. ................................................. 1275 kPa (185 psi) Minimum ............................................................. ................................................................................................................................... 959 kPa (139 psi) COMPRESSION PRESSURE DIFFERENCE OF ALL CYLINDER: Maximum ............................................................................................................................................. ...................................................... 98 kPa (14 psi) VACUUM: Manifold ............................................................................................................................................... .......................................... 60 kPa (18 inches Hg) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1025 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications Timing Belt: Specifications On 1995-97 Avenger & Sebring Coupe CA vehicles, replacement at 60,000 mile intervals is recommended but not required. On 1998-2000 Avenger & Sebring Coupe CA, CT & MS models, replacement at 60,000 mile intervals is recommended but not required. On all other Avenger & Sebring Coupe models, replace every 100,000 miles (if not previously replaced). On 1995-98 Cirrus, Sebring Convertible & Stratus models, replacement at 105,000 mile intervals is recommended but not required. On 1999 Sebring Convertible & 1999-2000 Cirrus & Stratus models, replace revery 105,000 miles or 84 months. On 2000 Sebring Convertible vehicles, replace every 105,000 miles or 84 months. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection Timing Belt: Service and Repair Cleaning and Inspection 1. Remove the upper left timing belt cover. 2. Inspect both sides of the timing belt drive & back. Replace belt if any of the following conditions exist. ^ Hardening of back rubber back side is glossy without resilience and leaves no indent when pressed with fingernail. ^ Cracks on rubber back. ^ Cracks or peeling of canvas. ^ Cracks on rib root. ^ Cracks on belt sides. ^ Missing teeth. ^ Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. 3. If none of the above conditions are seen on the belt. the belt cover can be reinstalled. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 1034 Timing Belt: Service and Repair Timing Belt Removal and Installation For timing cover removal and installation, See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair REMOVAL 1. Mark belt running direction for installation. 2. Loosen timing belt auto tensioner bolts and remove timing belt. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 1035 INSTALLATION 1. Set crankshaft sprocket to Top Dead Center (TDC) by aligning the sprocket with the mark on the oil pump housing, then back off to 3 notches before TDC. 2. Set camshaft sprockets to the aligning marks on the sprockets with the marks on the rear timing belt cover. 3. Install timing belt on rear camshaft sprocket first and install a binder clip on the belt and sprocket so the belt will not slip out of position. Keeping the belt taught, install under the water pump pulley and then around the front camshaft sprocket. Install an additional binder clip on the front sprocket and belt. 4. Rotate the crankshaft to TDC. Continue routing the belt by the idler pulley and around the crankshaft sprocket to the tensioner Pulley 5. Apply rotating force to the crankshaft sprocket in the clockwise direction, to tension belt, check that all timing marks are aligned. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 1036 6. Using Special Tool MD 998767, or equivalent and a torque wrench on the tensioner pulley. Apply 4.4 Nm (38.9 inch lbs.) of torque to tensioner. Tighten tensioner pulley bolt to 48 Nm (35 ft. lbs.). 7. With torque being applied to the tensioner pulley install the tensioner to the tensioner pulley bracket and tighten fasteners to 23 Nm (205 inch lbs.). 8. Pull tensioner plunger pin. 9. Rotate crankshaft 2 revolutions in a clockwise direction ONLY and check the alignment of the timing marks. Install tensioner pin into assembly. The pin should slide in and out without any resistance. If the pin does not slide freely, perform the procedure again. 10. Install front half of timing cover and engine mount bracket. 11. Install right engine mount. 12. Remove jack from under engine. 13. Install crankshaft damper and crankshaft damper bolt and tighten to 182 Nm (134 ft. lbs.). 14. Install accessory drive belts. 15. Raise vehicle on hoist and install right inner splash shield. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 1037 Timing Belt: Service and Repair Camshaft and Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > A/C Belt Tension Drive Belt: Specifications A/C Belt Tension New ..................................................................................................................................................... ...................................................................... 150 lbs. Used .................................................................................................................................................... ......................................................................... 80 lbs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > A/C Belt Tension > Page 1042 Drive Belt: Specifications Alternator Belt Tension New ..................................................................................................................................................... ...................................................................... 150 lbs. Used .................................................................................................................................................... ......................................................................... 80 lbs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > A/C Belt Tension > Page 1043 Drive Belt: Specifications Power Steering Belt Tension New ..................................................................................................................................................... ...................................................................... 130 lbs. Used .................................................................................................................................................... ......................................................................... 80 lbs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1044 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1045 Drive Belt: Description and Operation The engine is equipped with 2 drive belts. One belt drives the power steering pump, the other drives the generator and air conditioning. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1046 Drive Belt: Testing and Inspection Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment Drive Belt: Adjustments A/C Belt Adjustment To adjust the air conditioning and generator drive belt, loosen the idler pulley bolt and adjust belt tension by turning adjusting screw. Tighten pulley bolt to 54 Nm (40 ft. lbs.) after adjustment. For conventional belts and Poly-V belts, use belt tensioning Special Tool Kit C-4162 to obtain proper belt tension. Adjust the belt tension for a New or Used belt as prescribed in specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment > Page 1049 Drive Belt: Adjustments Alternator Belt Adjustment To adjust the air conditioning and generator drive belt, loosen the idler pulley bolt and adjust belt tension by turning adjusting screw. Tighten pulley bolt to 54 Nm (40 ft. lbs.) after adjustment. For conventional belts and Poly-V belts, use belt tensioning Special Tool Kit C-4162 to obtain proper belt tension. Adjust the belt tension for a New or Used belt as prescribed in specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment > Page 1050 Drive Belt: Adjustments Power Steering Pump Belt Adjustment For conventional belts and Poly-V belts, use belt tensioning Special Tool Kit C-4162 to obtain proper belt tension. Adjust the belt tension for a New or Used belt as prescribed in specifications. 1. From the top of the vehicle loosen pivot bolt. 2. From under the vehicle loosen the locking bolts D and E. 3. Adjust belt tension with 1/2 inch breaker bar installed in adjusting bracket. 4. Tighten locking bolt E to 28 Nm (250 inch lbs.). 5. Tighten locking bolt D and the pivot bolt to 54 Nm (40 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt Drive Belt: Service and Repair A/C Belt To remove and install the air conditioning compressor and generator drive belt, first loosen the idler pulley lock bolt, then turn the adjusting screw to increase or decrease the idler pulley tension. To adjust the air conditioning and generator drive belt, loosen the idler pulley bolt and adjust belt tension by turning adjusting screw. Tighten pulley bolt to 54 Nm (40 ft. lbs.) after adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1053 Drive Belt: Service and Repair Alternator Belt To remove and install the air conditioning compressor and generator drive belt, first loosen the idler pulley lock bolt, then turn the adjusting screw to increase or decrease the idler pulley tension. To adjust the air conditioning and generator drive belt, loosen the idler pulley bolt and adjust belt tension by turning adjusting screw. Tighten pulley bolt to 54 Nm (40 ft. lbs.) after adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1054 Drive Belt: Service and Repair Power Steering Belt 1. From the top of the vehicle loosen pivot bolt. 2. From under the vehicle loosen the locking bolts D and E. 3. Install the belt. Adjust belt tension with 1/2 inch breaker bar installed in adjusting bracket. 4. Tighten locking bolt E to 28 Nm (250 inch lbs.). 5. Tighten locking bolt D and the pivot bolt to 54 Nm (40 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Page 1055 Belt Tension Gauge C-4162 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Housing And Element REMOVAL 1. Unfasten clasps on rear of air cleaner housing cover. Lift cover off air cleaner housing. Air Cleaner Housing And Element 2. Remove filter element. 3. If necessary clean the inside of the air cleaner housing. INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps in place. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > A/T - 41TE/42LE Shudder During EMCC Shift > Page 1065 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 1068 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1073 Fuel Pressure Release: Service and Repair Fig. 2 Releasing Fuel Pressure Fig. 1 Fuel Pressure Test Port--Typical CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock. 1. Disconnect the fuel rail electrical harness from the engine harness. Refer to Diagrams/Electrical. 2. Connect one end of a jumper wire to the A142 circuit terminal of the fuel rail harness connector. 3. Connect the other end of the jumper wire to a 12 volt power source. 4. Connect one end of a jumper wire to a good ground source. 5. Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector. Repeat procedure for 2 to 3 injectors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications To Adapter ........................................................................................................................................... ..................................................... 14 Nm (10 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1077 Oil Filter: Description and Operation All engines are equipped with a high quality full flow, disposable type oil filter. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1078 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 lockseam. The lockseam joining the can to the base is reinforced by the base plate. 1. Turn counter clockwise to remove. 2. To install, lubricate new filter gasket. Screw filter on until gasket contacts base. Tighten to 14 Nm (10 ft.lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair Fig 57 Heater Hose Connection At Engine NOTE: The heater hoses used are preformed hoses with quick connect fittings at the engine. These hoses are not serviceable and must be replaced using OEM parts. The hoses are attached at the heater core using spring tension clamps. NOTE: Review Safety Precautions and Warnings before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Using thin slide-jaw pliers, pinch quick connect fitting in, of hose to be removed. 3. Remove intake manifold plenum. Fig 56 Heater Hose Connection At Heater Core 4. Using spring tension clamp pliers, remove clamp at heater core end of hose to be removed. 5. Carefully rotate hose back and forth while tugging slightly away from connector nipple. 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 into heater unit. INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Refrigerant Oil Capacity All Refrigerant Lines ............................................................................................................................ ....................................................... 44 ml (1.5 oz) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1086 Hose/Line HVAC: Description and Operation A/C REFRIGERANT LINES The lines are used to carry the refrigerant between the various system components. The air conditioning lines used on this vehicle are made from reinforced rubber with a nylon liner on the inner walls. The ends of the A/C lines are made with light weight aluminium fittings or quick connects. The A/C lines use special connectors called quick connects. There are four quick connects in the system. Two are located at the condenser and the other two are located at the expansion valve. Each quick connector has a clip installed on it. CAUTION: Never attempt to remove a clip or disconnect a quick connect without reclaiming all refrigerant from the air conditioning system. The system must be empty. All quick connects use two O-rings to seal the connection. The O-rings are made from a special type of rubber that is not affected by R-134a refrigerant. O-ring replacement is required whenever lines are removed and installed. Use only O-rings specified for this vehicle. Failure to use the correct type of O-ring will cause the connection to leak within a short period of time. When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a Service equipment or vehicle a/c system should not be pressure tested or leak tested with compressed air. Some mixtures of air/R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert into acids within a closed system. CAUTION: The system must be completely empty before opening any filling or connection in the refrigeration system. Open fillings with caution even after the system has been emptied. If any pressure is noticed as a filling is loosened, retighten fitting and evacuate the system again. A good rule for the flexible hose lines is to keep the radius of all bends at least 10 times the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 3 inches (80 mm) from the exhaust manifold. Inspect all flexible hose lines to make sure they are in good condition and properly routed. The use of correct wrenches when making connections is very important. Improper wrenches or improper use of wrenches can damage the fittings. The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. When opening a refrigeration system, have everything you will need to repair the system ready. This will minimize the amount of time the system must be opened. Cap or plug all lines and fittings as soon as they are opened. This will help prevent the entrance of dirt and moisture. All new lines and components should be capped or sealed until they are ready to be used. All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept clean and dry. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings Hose/Line HVAC: Service and Repair Handling Tubing and Fittings HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert to acids within a closed system. CAUTION: The system must be completely empty before opening any fitting or connection on the refrigerant system. Open fittings with caution even after system has been emptied. If pressure is noticed as a fitting is loosened, tighten fitting and evacuate system again. BENDING FLEX HOSE A good rule for the flexable hose lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharper bends will reduce the flow of the refrigerant. The flexible hose lines should be routed at least 3 inches away from exhaust manifolds. Inspect all flexible hose lines to make sure they are in good condition and properly routed. CAUTION: The use of correct wrenches when making connections is very important. Improper wrenches or the improper use of wrenches can damage the fittings. INTERNAL DAMAGE The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture, or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. OPENING SYSTEM When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or Plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. CAUTION: All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept dry. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 1089 Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Fig 32 Quick Connect Clip Fig 33 Special Tool For Line At Condenser REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Disconnect A/C pressure transducer wire harness. 3. Remove quick connect clip and disconnect quick connect at condenser using Special Tool kit 7193. CAUTION: Cap all lines that are not being replaced and cap the expansion valve tubes. Fig 34 Line At Compressor 4. Disconnect line at A/C compressor. Remove discharge line. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 1090 INSTALLATION For installation, reverse the above procedures. Tighten bolts to 22 Nm (200 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 1091 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Fig 58 Liquid Line Clip At Expansion Valve LIQUID LINE TO EXPANSION VALVE Removal 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Remove A/C quick connect clip at expansion valve. Fig 59 Use Special Tool 7240 For Quick Connect 3. Disconnect quick connector on expansion valve. Remove liquid line from expansion valve. Use Special Tool kit 7193 to disconnect quick connector. CAUTION: Cap all lines that are not being replaced and cap the expansion valve tubes. Fig 60 Liquid Line At Receiver/Drier Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 1092 4. Disconnect liquid line from the receiver/drier. 5. Remove the liquid line from the vehicle. Installation For installation, reverse the above procedures. Fig 61 Clip Removal LIQUID LINE TO CONDENSER Removal 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Remove A/C quick connect clip at condenser. Fig 62 Quick Coupler Using Special Tool 7240 Fig 63 Line At Condenser 3. Disconnect quick connector at condenser. Remove liquid line from condenser. Use special tool kit 7193 to disconnect quick connector. Remove line at condenser. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 1093 CAUTION: Cap all lines that are not being replaced and cap the condenser inlet. Fig 64 Liquid Line At Receiver/Drier 4. Disconnect liquid line from the receiver/drier. 5. Remove the liquid line from the vehicle. Installation For installation reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 1094 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Fig 70 Suction Line Routing Clip REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Remove suction line clip at right strut tower. Fig 71 Quick Connect Clip 3. Remove quick connect clip. Disconnect quick connect at expansion valve end using Special Tool Kit 7193. CAUTION: Cap all lines that are not being replaced and cap the expansion valve tubes. Fig 72 Suction Line At Compressor 4. Disconnect line at compressor end. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 1095 5. Remove suction line from vehicle. INSTALLATION For installation, reverse the above procedures. Tighten bolts to 22 Nm (200 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-06-96 > Dec > 96 > Power Steering Pump Moaning Noise Power Steering Line/Hose: Customer Interest Power Steering Pump - Moaning Noise NO: 19-06-96 GROUP: Steering DATE: Dec. 6, 1996 SUBJECT: Power Steering Pump Noise MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Moaning noise from power steering pump. Noise will increase with steering input and temperature. DIAGNOSIS: Check power steering fluid level, adjust as required. Listen for power steering pump moaning noise. If noise increases with steering input and temperature perform Repair Procedure. PARTS REQUIRED: AR(1) 04764347AA Hose, Power Steering Pressure, 2.0L/2.4L Engine AR(1) 04764349AA Hose, Power Steering Pressure, 2.5L Engine REPAIR PROCEDURE: This bulletin involves replacing the power steering pressure hose with a revised part. 1. Install the revised power steering pressure hose as described on page 19-14 of the 1997 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-7121). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-10-93 2.8 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-06-96 > Dec > 96 > Power Steering Pump - Moaning Noise Power Steering Line/Hose: All Technical Service Bulletins Power Steering Pump - Moaning Noise NO: 19-06-96 GROUP: Steering DATE: Dec. 6, 1996 SUBJECT: Power Steering Pump Noise MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Moaning noise from power steering pump. Noise will increase with steering input and temperature. DIAGNOSIS: Check power steering fluid level, adjust as required. Listen for power steering pump moaning noise. If noise increases with steering input and temperature perform Repair Procedure. PARTS REQUIRED: AR(1) 04764347AA Hose, Power Steering Pressure, 2.0L/2.4L Engine AR(1) 04764349AA Hose, Power Steering Pressure, 2.5L Engine REPAIR PROCEDURE: This bulletin involves replacing the power steering pressure hose with a revised part. 1. Install the revised power steering pressure hose as described on page 19-14 of the 1997 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-7121). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-10-93 2.8 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1109 Power Steering Line/Hose: Specifications Hose Tube Nuts ................................................................................................................................... ..................................................... 54 Nm (40 ft. lbs.) Return Hose Bracket To Head ......................... ......................................................................................................................................... 28 Nm (21 ft. lbs.) Pressure Hose to Return Hose Bracket .................................................................................................................................................... 9 Nm (75 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1110 Power Steering Line/Hose: Testing and Inspection SYMPTOM/CONDITION Moaning noise from power steering pump. Noise will increase with steering input and temperature. DIAGNOSIS Check power steering fluid level, adjust as required. Listen for power steering pump moaning noise. If noise increases with steering input and temperature, refer to TSB # 19-06-96, dated 12/06/96 for a possible repair procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump REMOVE 1. Using a siphon pump, remove as much power steering fluid as possible from the remote power steering fluid reservoir. CAUTION: Care must be used when removing the power steering fluid supply hose from power steering fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steering fluid reservoir, nipple can break off of the reservoir. Fig. 8 2. Remove hose clamp, attaching power steering fluid supply hose to the power steering fluid reservoir. Then remove power steering fluid supply hose from power steering fluid reservoir. 3. Raise vehicle. 4. Remove hose clamp, attaching power steering fluid supply hose to the power steering pump. Then remove power steering fluid supply hose from power steering pump fitting. INSTALL 1. Install power steering fluid supply hose on power steering pump fitting, making sure it is correctly routed up to the power steering fluid reservoir. Install hose clamp on power steering fluid supply hose at power steering pump fitting. Be sure hose clamp is installed on power steering fluid supply hose past upset bead on power steering pump fitting. 2. Lower vehicle. CAUTION: Care must be used when installing power steering fluid supply hose on power steering fluid reservoir. If excessive force is used when trying to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir. 3. Install power steering fluid supply hose on power steering fluid reservoir fitting. Install hose clamp on power steering fluid supply hose at power Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1113 steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 4. Fill power steering fluid reservoir. 5. Start the engine and let run for a few seconds. Then turn the engine off. 6. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 7. Raise front wheels of vehicle off the ground. 8. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 9. Add power steering fluid if necessary. 10. Lower the vehicle and turn the steering wheel slowly from lock to lock. 11. Stop the engine. Check the fluid level and refill as required. 12. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 13. After hose is installed, check for leaks at all hose connections. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1114 Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. NOTES: - To service the power steering pressure hose on this vehicle, the front suspension crossmember and steering gear will need to be lowered away from the body and frame of the vehicle. This is required for access to the power steering hose connections on the side of the steering gear. - Service all power steering hoses with the vehicle raised on a hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent the entry of foreign material into the components. REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. CAUTION: When lowering the front suspension crossmember, its installed position on the vehicle's body must be marked on the crossmember before it is lowered. 2. Lower the front suspension crossmember far enough to gain access to the high and low pressure ports on the steering gear. 3. Disconnect the power steering pressure hose at the power steering gear. Drain power steering fluid from power steering pump and hose through open end of hose. 4. Remove the 2 routing brackets attaching the power steering return hose to the power steering pressure hose routing brackets. Then remove the 2 bolts attaching the power steering pressure hose routing brackets to the cylinder head. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1115 5. Remove the tie-strap holding the power steering fluid supply hose to the power steering pressure hose. 6. Remove the power steering pressure hose from the pressure fitting on power steering pump. 7. Power steering fluid pressure hose is removed from the vehicle from the bottom rear of engine compartment. 8. Discard all used O-rings located at ends of power steering pressure hose fittings. INSTALL 1. Install power steering pressure hose in vehicle from bottom of engine compartment using the reverse order of removal. 2. Using a lint free towel, wipe clean all open power steering hose ends, and the power steering pump and steering gear ports. 3. Install new O-rings on the power steering pressure hose fittings. 4. Lubricate both O-rings using fresh clean power steering fluid. 5. Attach power steering pressure hose to outlet; fitting on power steering pump. Do not tighten or torque pressure fitting at this time. CAUTION: Hoses must remain away from exhaust system, vehicle components and unfriendly surfaces causing possible damage to power steering hoses. 6. Correctly route power steering pressure hose avoiding tight bends or kinking of the hose. Install power steering pressure hose routing brackets and attaching bolts on engine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1116 7. Route power steering pressure hose to pressure port on power steering gear. Install power steering pressure hose, on steering gear and loosely install tube nut into steering gear. Then using a crow foot, tighten the power steering pressure hose tube nut to a torque of 31 Nm (275 inch lbs.). CAUTION: When installing the front suspension crossmember, it must be installed back in the same location on the vehicle's body as when it was originally installed when the vehicle was built. 8. Raise the front suspension crossmember and steering gear back up into the vehicle. Refer to the steering gear service procedure in this group of the service manual for the required procedure to install the front suspension crossmember. CAUTION: The tie strap must be installed on the power steering pressure hose and supply hose to ensure proper routing of the hoses. 9. Install the tie-strap holding the power steering fluid supply hose to the power steering pressure hose. 10. Lower vehicle. 11. Start the engine and let run for a few seconds. Then turn the engine off. 12. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 13. Raise front wheels of vehicle off the ground. 14. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 15. Add power steering fluid if necessary. 16. Lower the vehicle and turn the steering wheel slowly from lock to lock. 17. Stop the engine. Check the fluid level and refill as required. 18. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 19. After hose is installed, check for leaks at all hose connections. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1117 Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose Removal WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. NOTES: - To remove the power steering return hose on this vehicle, the front suspension crossmember and steering gear will need to be lowered away from the body of the vehicle. This is required for access to the power steering hose connections on the side of the steering gear. Refer to the steering gear service procedure in this group of the service manual for the required procedure to remove the front suspension crossmember. - Service all power steering hoses with the vehicle raised on a hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent the entry of foreign material into the components. 1. Siphon all power steering fluid from the power steering fluid reservoir. CAUTION: Care must be used when removing power steering fluid return hose from power steering fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steering fluid reservoir, nipple can break off of the reservoir. 2. Remove power steering fluid return hose from nipple on power steering fluid reservoir. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. CAUTION: When lowering the front suspension crossmember, its installed position on the vehicle's body must be marked on the crossmember before it is lowered. 4. Lower the front suspension crossmember far enough to gain access to the high and low pressure ports on the steering gear. 5. Disconnect power steering fluid return hose at power steering gear. Drain power steering fluid from hose. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1118 6. Remove the 2 routing brackets attaching the power steering return hose to the power steering pressure hose routing brackets. 7. Remove the power steering return hose from the vehicle. The power steering return hose is removed from the bottom of the engine compartment. Installation 1. Install power steering return hose on vehicle. Power steering return hose is installed from the bottom of the vehicles engine compartment using the reverse steps of removal. 2. Using a lint free towel, wipe clean all open power steering hose ends, and the power steering gear port. 3. Install a new O-ring on the power steering return hose to steering gear fitting. 4. Lubricate O-ring using fresh clean power steering fluid. 5. Install power steering return hose, on steering gear and loosely, install tube nut into steering gear. Then using a crow foot, tighten the power steering pressure hose tube nut to a torque of 31 Nm (275 inch lbs.). CAUTION: Hoses must remain away from exhaust system, vehicle components and unfriendly surfaces causing possible damage to power steering hoses. 6. Correctly route power steering return hose up to the power steering fluid reservoir, avoiding tight bends or kinking of the hose. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1119 7. Install the 2 routing brackets attaching the power steering return hose to the power steering pressure hose routing brackets. CAUTION: When installing the front suspension crossmember, it must be installed back in the same location on the vehicle's body as when it was originally installed when the vehicle was built. 8. Raise the front suspension crossmember and steering gear back up into the vehicle. 9. Lower vehicle. CAUTION: Care must be used when installing power steering fluid return hose on power steering fluid reservoir. If excessive force is used when trying to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir. 10. Install power steering return hose on power steering fluid reservoir fitting. Install hose clamp on power steering return hose at power steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. 11. Start the engine and let run for a few seconds. Then turn the engine off. 12. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 13. Raise front wheels of vehicle off the ground. 14. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 15. Add power steering fluid if necessary. 16. Lower the vehicle and turn the steering wheel slowly from lock to lock. 17. Stop the engine. Check the fluid level and refill as required. 18. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 19. After hose is installed, check for leaks at all hose connections. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1120 Power Steering Line/Hose: Service and Repair Power Steering Fluid Cooler Lines Removal 1. Remove intermediate steering shaft coupler from the steering gear shaft. 2. Siphon as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle using a frame contact type hoist or supported as required using jack stands. 4. Remove the left front wheel/tire. 5. Remove the front fascia and the grill as an assembly from the vehicle. 6. Remove the hose clamps from the power steering fluid hoses. Drain power steering fluid from the hoses and the power steering fluid cooler. 7. Remove-the-bracket attaching the power steering fluid cooler lines to the left front frame rail. 8. Lower the front suspension crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1121 9. Remove the clip holding the power steering fluid cooler lines together. 10. Remove the hose clamp attaching the power steering fluid return hose from the engine, to the power steering fluid cooler lines. 11. Remove the power steering fluid return hose from the power steering gear. 12. Remove the power steering fluid cooler lines from the routing clip on the left front frame rail. 13. Separate the power steering cooler line assembly into 2 separate pieces. 14. Remove each cooler line separately from the vehicle. The cooler lines are removed out through the front of the vehicle in the area between the radiator and the closure panel. Installation 1. Install the cooler lines individually using the reverse procedure of their removal. 2. Install the cooler lines in the routing clip on the left frame rail. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1122 3. Install the power steering fluid return hose coming from the engine on the power steering cooler line. Install the hose clamp on the power steering fluid hose. Be sure hose clamp is installed on hose past the upset bead on the power steering cooler line. 4. Install the power steering fluid return hose on the steering gear. Then using a crow foot and torque wrench tighten the tube nut to a torque of 31 Nm (275 inch lbs.). 5. Install the-clip holding the 2 power steering fluid cooler lines together. 6. Install the front suspension crossmember. 7. Install the left front wheel/tire. 8. Install the bracket attaching the power steering cooler lines to the left frame rail. Install bracket attaching bolt and tighten to a torque of 7 Nm (60 inch lbs.). 9. Install power steering fluid hoses on the power steering fluid cooler. Install the hose clamps on the power steering fluid hoses. Be sure hose clamps are installed on hose past the upset bead on the power steering oil cooler. 10. Install the front fascia and grill on the vehicle. 11. Lower the vehicle to a point where front tires are just off the ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1123 12. Connect the steering column intermediate shaft on the shaft of the steering gear. Install the coupler retaining pinch bolt and tighten to a torque of 27 Nm (240 inch lbs.). Be sure to install the coupler retaining pinch bolt retention pin. 13. Start the engine and let run for a few seconds. Then turn the engine off. 14. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 15. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 16. Add power steering fluid if necessary. 17. Stop the engine. Check the fluid level and refill as required. 18. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTER-CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE. CAUTION: ^ Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing constant tension clamps. ^ A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter. HOSES Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. CLAMPS Spring type hose clamps are used in all applications. If replacement is necessary replace with the original Mopar equipment spring type clamp. The hose clamps are removed by using Special Tool 6094, or equivalent constant tension clamp pliers to compress hose clamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1131 Brake Fluid: Service Precautions CAUTION: Use only Mopar brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1132 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1133 Brake Fluid: Service and Repair Master Cylinder Fluid Level CAUTION:Use only Mopar brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Check master cylinder reservoir brake fluid level a minimum of twice a year. Master cylinder reservoirs are marked with the words FULL AND MIN indicating proper range of the master cylinder fluid level. If necessary, add specified brake fluid bringing level to the FULL mark on the side of the master cylinder brake fluid reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1138 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ........................................................ 10.0 L (10.5 qts) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1141 Coolant: Fluid Type Specifications GENERAL INFORMATION Performance is measurable. For heat transfer pure water absorbs 1 btu for each degree of temperature rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: ^ Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). ^ 100 Percent ethylene glycol (0.7 btu) can cause an engine to run hot, cause detonation, and will freeze at -22°C (-8°F). ^ 50/50 Ethylene Glycol and Distilled Water (0.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, coolant sensor and heater are all designed for 50/50 ethylene glycol. ^ Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -46°C ( -50°F ). NOTE: Richer mixtures cannot be measured with field equipment and can lead to problems associated with 100 percent glycol. If there is doubt that the coolant mixture is to rich for field equipment to measure, put a sample in a clean container. Add exactly the same amount of water and retest. If the coolant in the vehicle is 100% antifreeze, the diluted sample will read 50%. If the coolant in the vehicle was 70% antifreeze and 30% water, the diluted sample will read as 35%, etc. SELECTION AND ADDITIVES The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or their equivalent are recommended for best engine cooling without corrosion. When mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it looses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspected water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information GENERAL INFORMATION The cooling system is designed around the coolant. PICKING UP HEAT The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. GIVING OFF HEAT Then carry this heat to the radiator where the tube/fin assemblies of these components can give off the heat to the air. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information > Page 1144 Coolant: Description and Operation Coolant Performance GENERAL INFORMATION Performance is measurable. For heat transfer pure water absorbs 1 btu for each degree of temperature rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: ^ Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). ^ 100 Percent ethylene glycol (0.7 btu) can cause an engine to run hot, cause detonation, and will freeze at -22°C (-8°F). ^ 50/50 Ethylene Glycol and Distilled Water (0.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, coolant sensor and heater are all designed for 50/50 ethylene glycol. ^ Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -46°C ( -50°F ). NOTE: Richer mixtures cannot be measured with field equipment and can lead to problems associated with 100 percent glycol. If there is doubt that the coolant mixture is to rich for field equipment to measure, put a sample in a clean container. Add exactly the same amount of water and retest. If the coolant in the vehicle is 100% antifreeze, the diluted sample will read 50%. If the coolant in the vehicle was 70% antifreeze and 30% water, the diluted sample will read as 35%, etc. SELECTION AND ADDITIVES The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or their equivalent are recommended for best engine cooling without corrosion. When mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it looses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspected water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1145 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1150 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1151 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1152 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1153 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1154 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1155 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1156 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transaxle/Transmission - Automatic Transmission Fluid Service Refill Capacity ......................................................................................................................... ............................................................. 3.8L (4.0 Qt) Initial Refill Capacity Transmission Fluid Initial Refill Capacity ............................................................................................................................ ............................................................ 3.8L (4.0 Qt) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1159 Fluid - A/T: Fluid Type Specifications Oil Type ........................................................................................................................................................... MOPAR ATF+4 Type 9602, Or Equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1162 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1163 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ............................................. 1.9-2.2L (4.0-4.6 Pints) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1168 Fluid - M/T: Fluid Type Specifications NV T350 .............................................................................................................................................. ........................................................... 2.1 L (2.2 qts.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications Fluid - Differential: Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ........................................................ 0.9L (1.9 Pints) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.3L (4.5 Qt) Without Filter Change ....................................... ................................................................................................................................................ 3.8L (4.0 Qt) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1176 Engine Oil: Fluid Type Specifications Engine Oil API Classification .............................................................................................................................................................. SJ ECII or SJ/CD ECII or Above Above 0°F (-18°C)............................................................................ .......................................................................................................................... 10W-30 Below 100°F (38°C)................................................................................................................................................... .................................................. 5W-30 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Technician Safety Information > Page 1179 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1180 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1181 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service Precautions > Page 1182 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1191 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1197 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1198 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1199 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1204 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1210 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1211 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1212 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1213 Power Steering Fluid: Specifications The OE Service Manual does not provide a Power Steering Fluid Type Specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1214 Power Steering Fluid: Service and Repair WARNING: Fluid level should be checked with engine off to prevent injury from moving parts. Do not use automatic transmission fluid in the power steering system. Do not overfill the power steering system. Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approximately 21°C - 27°C (70°F - 80°F). In all pumps add fluid as necessary, use only Mopar Power Steering Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C Refrigerant/Oil - Capacity Revisions Refrigerant: Technical Service Bulletins A/C Refrigerant/Oil - Capacity Revisions NO: 24-19-96 GROUP: Air Conditioning DATE: Nov. 22, 1996 SUBJECT: A/C Performance MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus DISCUSSION: The type and quantity of refrigerant oil used in JA vehicles has been changed to enhance performance. The oil capacity of the total air conditioning system has been reduced to 5.0 ft. oz. (150 ml.) from 7.0 fl.oz. The oil designated for JA vehicles is SP-15 PAG (revised from SP-10), P/N 04886129AA. Following procedures/guidelines will maximize A/C system performance during routine service and diagnosing complaints of poor A/C performance. System Refrigerant Charge: ^ 1995-1996 vehicles, charge to 28 fl.oz. ^ 1997 vehicles, charge to 26 fl.oz. ^ All vehicles: To obtain the proper system refrigerant charge level using reclaim/recycling equipment, add an additional 2 fl.oz. of refrigerant per charging hose to account for charging hose capacity. Reference SUN STAND owners manual section "USING THE AUTO SEQUENCE FEATURE" (or equivalent). ^ The recommended procedure to check charge level is the "Partial Charge Test" (using the DRB III and a thermocouple). System Oil Level: ^ For vehicles built before April 1, 1996 (MDH 04-01-XX), remove 2.0 fl.oz. of oil from compressor. ^ For vehicle built after April 1, 1996 (MDH 04-01-XX), do not remove 2.0 fl.oz. of oil from compressor. ^ During routine service, use only SP-15 PAG refrigerant oil, Mopar P/N 04886129AA. 2.5L Engine Equipped Vehicles: ^ TSB 24-07-96 Rev. A should be performed on all 2.5L equipped vehicles with A/C performance complaints. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Capacity ................................................................................................................................... ......................................... 0.79 kg (28 oz or 1.75 lbs) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1221 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1222 Refrigerant: Description and Operation REFRIGERANT The R-134a refrigerant used in this air conditioning system is a non-toxic, non-flammable, clear, and colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to a R-134a refrigerant system, will cause compressor failure, refrigerant oil sludge, or poor air conditioning system performance. The refrigerant system service ports have been designed to ensure that the system is not accidentally filled with the wrong refrigerant (R-12). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Refrigerant/Oil - Capacity Revisions Refrigerant Oil: Technical Service Bulletins A/C Refrigerant/Oil - Capacity Revisions NO: 24-19-96 GROUP: Air Conditioning DATE: Nov. 22, 1996 SUBJECT: A/C Performance MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus DISCUSSION: The type and quantity of refrigerant oil used in JA vehicles has been changed to enhance performance. The oil capacity of the total air conditioning system has been reduced to 5.0 ft. oz. (150 ml.) from 7.0 fl.oz. The oil designated for JA vehicles is SP-15 PAG (revised from SP-10), P/N 04886129AA. Following procedures/guidelines will maximize A/C system performance during routine service and diagnosing complaints of poor A/C performance. System Refrigerant Charge: ^ 1995-1996 vehicles, charge to 28 fl.oz. ^ 1997 vehicles, charge to 26 fl.oz. ^ All vehicles: To obtain the proper system refrigerant charge level using reclaim/recycling equipment, add an additional 2 fl.oz. of refrigerant per charging hose to account for charging hose capacity. Reference SUN STAND owners manual section "USING THE AUTO SEQUENCE FEATURE" (or equivalent). ^ The recommended procedure to check charge level is the "Partial Charge Test" (using the DRB III and a thermocouple). System Oil Level: ^ For vehicles built before April 1, 1996 (MDH 04-01-XX), remove 2.0 fl.oz. of oil from compressor. ^ For vehicle built after April 1, 1996 (MDH 04-01-XX), do not remove 2.0 fl.oz. of oil from compressor. ^ During routine service, use only SP-15 PAG refrigerant oil, Mopar P/N 04886129AA. 2.5L Engine Equipped Vehicles: ^ TSB 24-07-96 Rev. A should be performed on all 2.5L equipped vehicles with A/C performance complaints. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ .......................................................... 150 ml. 5.00 oz. Condenser ........................................................................................................................................... ............................................................. 30 ml. 1.00 oz. Evaporator ........................................................................................................................................... ............................................................ 59 ml. 2.00 oz. Filter/Drier ............................................................................................................................................ .......................................................... 30 ml. 1.00 oz. A/C Lines ............................................................................................................................................. ........................................................... 44 ml. 1.50 oz. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1229 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. ......................................................................... SP-15 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1230 Refrigerant Oil: Service and Repair Refrigerant Oil Capacities SYSTEM OIL LEVEL It is important to have the correct amount of lubricant in the A/C system to ensure proper lubrication of the compressor. Too little lubricant will result in damage to the compressor. Too much lubricant will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. The lubricant used in the compressor is polyalkalene glycol PAG lubricant. Only refrigerant lubricant approved for use with R-134a should be used to service the system. Do not use any other lubricant. The lubricant container should be kept tightly capped until it is ready for use. Refrigerant lubricant will quickly absorb any moisture it comes in contact with. It is not necessary to check or add lubricant unless it has been lost. Lubricant loss at the leak point will be evident by the presence of a wet, shiny surface around the leak. REFRIGERANT OIL LEVEL CHECK When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with (R-134a) refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and receiver/drier will retain a significant amount of oil. Refer to the A/C Component Refrigerant Oil Capacities chart. 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 receiver/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 an A/C system the evaporator retains 60 ml. (2 oz.). The condenser retains 30 ml. (1 oz.) of oil, and system capacity may be 150 ml. (5.00 oz.) of oil. 150 ml. minus 90 ml. equals 60 ml. (2.00 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 SP15 PAG (polyalkalene glycol). VERIFY REFRIGERANT LUBRICANT LEVEL 1. Discharge refrigerant system using a recycling/ reclaiming equipment if a charge is present. 2. Disconnect refrigerant lines from A/C compressor Cap the open lines to prevent moisture from entering system. 3. Remove compressor from vehicle. 4. From suction and discharge ports on top of compressor, drain lubricant from compressor. 5. Add system capacity minus the capacity of components that have not been replaced. Refer to the A/C Component Refrigerant Oil Capacities chart above. Add lubricant through the suction and discharge ports on compressor. This is not to exceed 150 ml. (5.00 oz.) in total. 6. Install compressor and connect refrigerant lines. Then evacuate and charge refrigerant system. 7. Most reclaim/recycling equipment will measure the lubricant being removed. This is the amount of lubricant to be added back to the system. If a new compressor is being installed, drain lubricant from old compressor, measure the amount drained and discard old lubricant. Drain the lubricant from the new compressor into a clean container. Return the amount of lubricant measured from the old compressor, plus the amount reclaimed from the system back into the new compressor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures GENERAL INFORMATION The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The Antilock Brake System (ABS), particularly the Hydraulic Control Unit (HCU), should only be bled when the HCU is. replaced or removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During Bleeding Operations - be sure that the brake fluid level remains close to the FULL level in the reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The Bendix ABX-4 Brake System must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. Refer to Brakes Service and Repair for the proper bleeding procedure to be used. This brake system can be either pressure bled or manually bled. The ABS portion of brake system MUST be bled separately. This bleeding procedure requires the use of the DRB scan tool and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a Manual bleeding procedure or standard Pressure Bleeding Equipment. If the brake system is to be bled using pressure bleeding equipment, refer to Brakes Service and Repair. 1. Assemble and install all brake system components on vehicle making sure all hydraulic fluid lines are installed and properly torqued. System Diagnostic Connector Location 2. Connect the DRB scan tool to the diagnostics connector. The diagnostics connector is located under the lower instrument panel next to the left kick panel. 3. Using the DRB scan tool, check to make sure the CAB does not have any fault codes stored. If it does, remove them using the DRB scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Brakes Service and Repair. 5. Using the DRB scan tool, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and free of bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brake are operating correctly and that pedal is solid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1235 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Air Trapped In Brake System Method For Purging Air From Brake System Bleeder Screw CAUTION: - Before removing the Master Cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. - Use bleeder tank Special Tool C-3496-B, or equivalent with required adapter for the master cylinder reservoir to pressurize the hydraulic system for bleeding. NOTE: - For bleeding the ABS hydraulic system, refer to Hydraulic Control Unit. - Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. PROCEDURE When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1236 Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The following wheel sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel 1. Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain an steady stream of brake fluid. 3. After 4 to 8 ounces of fluid has been bled through the brake and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder. It must stay at the proper level so air will not be allowed to reenter the brake system through the master cylinder reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 1240 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. ARMING 1. Connect battery ground cable. 2. From PASSENGER side of vehicle, turn ignition switch to ON position. 3. The SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 4. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1246 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1247 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation CIRCUIT OPERATION The engine coolant temperature lamp is used to alert the operator that the coolant temperature has risen above the normal operating range. When the Powertrain Control Module (PCM) determines a problem, a message is sent across the CCD Bus to the Body Control Module (BCM). The PCM receives coolant temperature information from the engine coolant temperature sensor. This sensor uses a variable resistor to send a signal to the PCM indicating engine coolant temperature. The BCM processes this message and sends a signal on the CCD Bus to the instrument cluster for lamp illumination. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CIRCUIT OPERATION The check engine lamp is used to indicate to the operator a problem in the engine control system. If a problem is detected, the Powertrain Control Module (PCM) sends a message, over the CCD Bus, to the Body Control Module (BCM). The BCM interprets this message and sends a signal to the instrument cluster to illuminate the lamp. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. The bulb check operation is controlled by the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for complete details. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1267 Wheels: Specifications Lug Nuts .............................................................................................................................................. ................................. 115 - 155 Nm (85 - 115 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1268 Wheels: Description and Operation Fig. 1 Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use steel or cast aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment equipment. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser Duality or of a substitute design. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. CAUTION: Installing wheels without good metal-to-metal contact could cause loosening of wheel lug nuts. This could adversely affect the safety and handling of your vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information Wheels: Testing and Inspection General Information Wheels must be replaced if they: - Have excessive run out - Are bent or dented - Leak air - Have damaged wheel lug holes Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original equipment replacement wheels are available through the dealer. When obtaining replacement wheels from any other source, they must be equivalent in load carrying capacity. The wheel features (diameter, width, offset, brake clearance, and mounting configuration) must match the original equipment wheels. CAUTION: Failure to use original equipment replacement wheels may adversely affect the safety and handling of your vehicle. CAUTION: Replacement with used wheels is not recommended. The service history of the rim may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1271 Wheels: Testing and Inspection Tire and Wheel Runout GENERAL INFORMATION Radial run out is the vertical distance between the high and low Print no the tire or wheel edge. Lateral run out is the horizontal movement of the tire or wheel. Radial run out of more than 0.762 mm (0.030 inch) measured at the center line of the tread may cause the vehicle to shake. Lateral run out of more than 0.762 mm (0.030 inch) measured near the shoulder of the tire may cause the vehicle to shake. Runout should always be measured off the vehicle and on a suitable balance machine. Usually radial run out can be reduced by relocating the wheel and tire on the wheel studs (See Method 1). If this does not reduce run out to an acceptable level, the tire can be rotated on the wheel. (See Method 2). Method 1 (Relocate Wheel On Hub) Check accuracy of the wheel mounting surface; adjust wheel bearings. - Drive vehicle a short distance to eliminate tire flat spotting from a parked position. Fig. 2 - Verify all wheel nuts are properly torqued. Fig. 3 - Use run out gauge D-128-TR, or equivalent to determine run out. - Relocate wheel on the mounting, two studs over from the original position. - Retighten wheel nuts until all are properly torqued. This will prevent brake distortion. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1272 - Check radial run out. If still excessive, mark tire sidewall, wheel, and stud at point of maximum run out and proceed to Method 2. Method 2 (Relocate Tire On Wheel) Rotating tire on wheel is particularly effective when there is run out in both tire and wheel. - Remove tire from wheel and remount wheel on hub in former position. Fig. 5 - Check wheel radial run out. It should be no more than 0.762 mm (0.030 inch). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1273 Fig. 6 - Lateral run-out should be no more than 0.762 mm (0.030 inch). - If point of the most wheel radial run out is near original chalk mark, remount tire 45 degrees from its original spot. Recheck run out. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 1274 Wheels: Service and Repair Lug Nut Tightening Sequence To install the wheel and tire assembly, first position it properly on the mounting surface using the hub pilot as a guide. Then progressively tighten the lug nuts in the proper sequence to half of the required torque. Finally tighten the lug nuts in the proper sequence to 115 - 155 Nm (85 - 115 ft. lbs.). Never use oil or grease on studs or nuts. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Tighten front axle shaft stub to ...................................................................................................................... 203 Nm (150 ft. lbs) to 244 Nm (180 ft. lbs.) Tighten Rear Hub/Bearing Assembly Retaining Nut ............................................................................................................................ 250 Nm (185 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 1279 Wheel Bearing: Fluid Type Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1280 Wheel Bearing: Description and Operation All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. However, if servicing of a rear wheel bearing is required, refer to procedures in Testing and Inspection and Service and Repair for the inspection and replacement of the rear wheel bearing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1281 Wheel Bearing: Testing and Inspection The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1282 Wheel Bearing: Service and Repair REMOVE 1. Raise vehicle on jackstands or center on a frame contact type hoist. 2. Remove rear wheel and tire assembly. Rear Brake Drum Removal 3. Remove brake drum from rear hub/ bearing assembly. Rear Hub/Bearing Dust Cap 4. Remove dust cap from rear hub/bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1283 5. Remove hub/bearing assembly to rear spindle retaining nut. 6. Remove rear hub/bearing assembly from spindle. Hub/bearing is removed by pulling it straight off the spindle by hand. INSTALL 1. Install the hub/bearing assembly on the knuckle. Then install a NEW rear hub/bearing assembly retaining nut. Tighten the hub/ bearing assembly retaining nut to a torque of 250 Nm (185 ft. lbs.). 2. Install hub/bearing assembly dust cap, using a soft faced hammer. 3. Install brake drum on rear hub/bearing assembly. 4. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in criss cross pattern to one-half the specified torque. Then repeat pattern, fully tightening the stud nuts to a torque of 109 - 150 Nm (80 - 110 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Tightening 1995-96 Stratus/Cirrus/Breeze .............................................................................................................................................244 Nm (180 ft. lbs.) Tightening 1997 Stratus/Cirrus/Breeze ........................................................................................................... 203 Nm (150 ft. lbs.) to 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1292 Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque .................................................................................................................................... ................................ 109 - 150 Nm (80 - 110 ft. lbs.) Lug Nut Hex Size .............................................. .......................................................................................................................................................... 19 mm Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1293 Wheel Fastener: Specifications Wheel Stud Size Stud Size ............................................................................................................................................. ............................................................ M12 x 1.5 mm Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1294 Wheel Fastener: Service Precautions CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1295 Wheel Fastener: Description and Operation If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. Use the procedure and special tools shown in the service procedures section for the wheel mounting studs when replacing the wheel attaching studs. The hub and bearing assembly does not require removal from the steering knuckle or the rear knuckle to replace the wheel attaching studs in the hub and bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1296 Wheel Fastener: Service and Repair CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. NOTES: - The following procedure and special tools shown MUST be used-when replacing wheel attaching studs. - The hub and bearing assembly does not require removal from the steering knuckle to replace wheel attaching studs in the hub and bearing assembly. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. 3. Remove front disc brake caliper to steering knuckle attaching bolts. 4. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1297 5. Support brake caliper/adapter assembly using a wire hook and not by hydraulic hose. Fig. 60 6. Remove braking disc from front hub. 7. Install a lug nut on wheel stud to be removed from hub and bearing assembly, so threads on stud are even with end of lug nut. Rotate hub so stud requiring removal is aligned with notch cast into front of steering knuckle. Install Remover, Special Tool C-4150 on hub and bearing assembly flange and wheel stud. 8. Tighten down on special tool, this will push the wheel stud out of the hub and bearing flange. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1298 Fig. 62 INSTALL 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install braking disk back on front hub. 4. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 5. Install disc brake caliper assembly to steering knuckle attaching bolts and torque to 31 Nm (23 ft. lbs.). 6. Install front wheel and tire assembly. Install front wheel lug nuts and torque to 129 Nm (95 ft. lbs.). 7. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION PRESSURE (at 250 - 400 RPM): Standard .............................................................................................................................................. ................................................. 1275 kPa (185 psi) Minimum ............................................................. ................................................................................................................................... 959 kPa (139 psi) COMPRESSION PRESSURE DIFFERENCE OF ALL CYLINDER: Maximum ............................................................................................................................................. ...................................................... 98 kPa (14 psi) VACUUM: Manifold ............................................................................................................................................... .......................................... 60 kPa (18 inches Hg) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1304 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 65 ft.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1309 Camshaft Gear/Sprocket: Service and Repair REMOVAL 1. Hold camshaft sprocket with Special Tool 6847, or equivalent loosen and remove bolt and washer. 2. Remove camshaft sprocket from camshaft. INSTALLATION 1. Place camshaft sprocket on camshaft. 2. Install bolt and washer to camshaft. Using Special Tool 6847, or equivalent hold camshaft sprocket and torque bolt to 88 Nm (65 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1310 Holder 6847 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation Camshaft: Description and Operation Two overhead camshafts provide valve actuation one left (radiator side of cylinder bank) and one right. The distributor is directly driven by the right camshaft. Both camshafts are supported by four bearing journals integral with the head. A flange at the rear of the camshaft acts as a thrust collar. Right and Left camshaft driving sprockets are interchangeable. The sprockets and the engine water pump are driven by the timing belt. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 NOTE: Cylinder Head Must Be Removed REMOVAL 1. Remove the cylinder head covers. 2. Install auto lash adjuster retainers Special Tool MD-998443, or equivalent. These retainers hold the lash adjuster into position when the rocker arms are serviced. 3. Mark rocker arm shaft assemblies for installation. 4. Remove rocker arm shaft bolts. 5. Remove the timing belt and camshaft sprocket. 6. Remove cylinder head retaining bolts. Remove cylinder head from vehicle. 7. Remove thrust case from left head assembly and remove camshaft from the rear of the head. 8. Remove distributor from right head assembly and remove camshaft from the rear of the head. INSTALLATION 1. Lubricate camshaft journals. Install camshaft into the cylinder head carefully. 2. Install thrust case and tighten fasteners to 13 Nm (108 inch lbs.). 3. Install camshaft seal. Camshaft must be installed before the camshaft seal is installed. 4. Install camshaft sprocket and tighten to 88 Nm (65 ft. lbs.). 5. Install timing belt. 6. Install rocker arm assemblies in correct order as removed. Tighten the rocker arm assemblies in sequence shown to 31 Nm (276 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1316 Camshaft: Service and Repair Checking End Play 1. Oil camshaft journals and install camshaft without rocker arm assemblies. 2. Using a suitable tool, move camshaft as far rearward as it will go. 3. Zero dial indicator. 4. Move camshaft as far forward as it will go. 5. End play travel: 0.1 - 0.2 mm (0.004 - 0.008 inch). Max. Travel: 0.4 mm (0.016 inch). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1317 Camshaft: Service and Repair Lobe Inspection 1. Check oil feed holes for blockage. 2. Inspect cylinder head journals for wear. 3. Check camshaft bearing journals for scratches and worn areas. If light scratches are present, they may be removed with 400 grit sand paper. If deep scratches are present, replace the camshaft and check the cylinder head for damage. Replace the cylinder head if worn or damaged. Check the lobes for pitting and wear. If the lobes show signs of wear, check the corresponding rocker arm roller for wear or damage. Replace rocker arm if worn or damaged. If lobes show signs of pitting on the nose, flank or base circle; replace the camshaft. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Auto Lash Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Testing and Inspection Auto Lash Adjuster: Testing and Inspection A tappet-like noise may be produced from several items. Check the following items. 1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy. 2. Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour may be required. 3. During this time, turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature. 4. Low oil pressure. 5. The oil restrictor pressed into the vertical oil passage to the cylinder head is plugged with debris. 6. Air ingested into oil due to broken or cracked oil pump pick up. 7. Worn valve guides. 8. Rocker arm ears contacting valve spring retainer. 9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system. 10. Faulty lash adjuster. a. Check lash adjusters for sponginess while installed in cylinder head. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. b. Remove suspected lash adjusters, and disassemble Do not reuse retainer caps. Do not interchange parts and make sure that care and cleanliness is exercised in the handling of parts. c. Clean out dirt and varnish with solvent. d. Reassemble with engine oil. e. Check for sponginess. f. If still spongy, replace with new adjuster. NOTE: The automatic lash adjusters are precision units installed in machined openings in the valve actuating ends of the rocker arms. Do not disassemble the auto lash adjuster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 31 Nm (23 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm Assembly Rocker Arm Assembly: Description and Operation Rocker Arm Assembly Are of light weight die-cast with roller type follower operating against the camshaft. The valve actuating end of the rocker arms are machined for hydraulic lash adjusters, eliminating the need for periodic valve lash adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm Assembly > Page 1326 Rocker Arm Assembly: Description and Operation Rocker Arm Shaft GENERAL INFORMATION The shafts are retained by retaining caps and bolts. Four shafts are used, one for each intake and exhaust rocker arm assembly on each cylinder head. The hollow shafts provide a duct for lubricating oil flow from the cylinder head to the valve mechanisms. SHAFT SPRINGS Rocker shaft springs are used on the intake shafts ONLY to obtain the proper clearance between the intake rocker arms and the spark plug tubes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement Rocker Arm Assembly: Service and Repair Rocker Arm Replacement REMOVAL 1. Remove cylinder head cover. 2. Identify the rocker arm shaft assemblies before removal. 3. Install auto lash adjuster retainers, Special Tool MD-998443, or equivalent onto rocker arms. These retainers hold the lash adjusters into position when the rocker arms are serviced. 4. Loosen the attaching fasteners. Remove rocker arm shaft assemblies from cylinder head. 5. Mark rocker arm/hydraulic lash adjuster assemblies for reassembly in their original position. Remove rocker arm/hydraulic lash adjuster assembly. Lash adjusters are serviced as an assembly with the rocker arm. NOTE: The automatic lash adjusters are precision units installed in machined openings in the valve actuating ends of the rocker arms. Do not disassemble the auto lash aid. INSTALLATION Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement > Page 1329 1. Install rocker arm and shafts with the FLAT on the shafts facing the timing belt side of the right cylinder head. For the left cylinder head, install rocker arm and shafts with the FLAT on the shafts facing the transmission side of the engine. Install the retainers and spring clips in their original positions on the exhaust and intake shafts. 2. Tighten bolts to 31 Nm (276 in. lbs.) in sequence shown. 3. Remove auto lash adjuster retainers Special Tool MD-998443, or equivalent from rocker arms. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement > Page 1330 Rocker Arm Assembly: Service and Repair Inspection Rocker Arm Assembly Inspect the rocker arm/hydraulic lash adjuster assembly for wear or damage. Replace assembly as necessary. Rocker Arm Shaft The rocker arm shafts is hollow and is used as a lubrication oil duct. 1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if damaged or worn. 2. Check oil holes for clogging with small wire, clean as required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1331 Holders MD-998443 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance .................................................................................................................................................... 0.020-0.067 mm (0.0008-0.0028 in) Side Clearance .................................................................................................................................... ............................ 0.010-0.25 mm (0.004-0.010 in) Wear Limit ........................................................................................................................................... ................................................. 0.4 mm (0.015 in) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Clearance 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Connecting Rod Bearing Clearance > Page 1338 Connecting Rod Bearing: Service and Repair Measuring Clearances OIL CLEARANCE 1. Follow the procedures outlined in using plastigage. Refer to specifications. 2. Tighten nuts to 52 Nm (38 ft. lbs.). 3. Remove connecting rod cap and measure Plastigage. CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. SIDE CLEARANCE Using a feeler gauge, check connecting rod side clearance. Refer to specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts TORQUE: Cap Nut ............................................................................................................................................... .................................................. 51 Nm (37 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1343 Connecting Rod: Specifications Connecting Rod Specifications Length - Center to Center ....................................................................................................................................... 140.9 - 141.0 mm (5.547 - 5.551 inches) Parallelism - Twist .................................................................................... ......................................................................................... 0.05 mm (0.0019 inch) Torsion .................. .............................................................................................................................................................. ................. 0.1 mm (0.0039 inch) Big End Thrust Clearance ............................................................................................................................................. 0.10 0.25 mm (0.004 - 0.010 inch) Service Limit ......................................................................................... ................................................................................................ 0.4 mm (0.016 inch) Cap Nut ............. .............................................................................................................................................................. .......................... 51 Nm (37 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1344 Connecting Rod: Description and Operation The large end of the connecting rod has an oil jet hole for lubrication of the thrust side of the cylinder. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1345 Connecting Rod: Service and Repair REMOVAL 1. Identify pistons with matching cylinder. The pistons are not interchangeable from bank to bank. Pistons with the letter R and arrow toward the front of engine are to be installed in cylinders 1-3-5. Pistons with the letter L and arrow toward the front of engine are to be installed in cylinders 2-4-6. 2. Mark connecting rod and cap with cylinder number. 3. Remove piston rings. 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 with oil ring rail gap. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1346 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. 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. Install the piston and connecting rod assembly with the directional letter is located on the top of the piston with the arrow facing toward the camshaft sprocket. 7. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 51 Nm (37 ft. lb.). CAUTION: Piston assemblies are not to be interchanged from bank to bank. 9. Check alignment marks made during disassembly and that bearing position notches new or used are on the same side as shown. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications Crankshaft Main Bearing: Specifications Crankshaft Size Specifications Crankshaft Size Specifications End Play 0.05 - 0.25 mm (0.002 - 0.010 in.) Service Limit 0.4 mm (0.016 in.) Main Journal Diameter 60.000 mm 92.362 in.) Pin Diameter 50.000 mm (1.969 in.) Bearing Surface Out-of-Round 0.03 mm (0.001 in.) Max Bearing Surface Taper 0.005 mm (0.0002 in.) Max Bearing Oil Clearance 0.02 - 0.04 mm (0.0008 - 0.0016 in.) Undersize Service Bearings 0.25 - 0.50 - 0.75 mm (0.010 - 0.020 - 0.030 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications > Page 1351 Crankshaft Main Bearing: Specifications Torque Specifications Bearing Cap Bolt ................................................................................................................................. ..................................................... 94 Nm (69 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Bearing Installation Crankshaft Main Bearing: Service and Repair Bearing Installation INSTALLATION When the bearings need replacing, select and install the proper bearing by the following procedure. ^ Measure the crankshaft journal diameter and confirm its classification from the following. In the case of a bearing supplied as a service part, its identification color is painted at the position shown. NOTE: Service replacement parts have identification marks, but factory-assembled parts have no identification marks. Service crankshaft identification may have marks or paint at counterweight. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Bearing Installation > Page 1354 Crankshaft Main Bearing: Service and Repair Inspection Clearance Measurements OIL CLEARANCE Mechanical Measurement Measure the journal outside diameter and the main bearing inside diameter. If the clearance exceeds the specifications limit. Replace the main bearing(s) and if necessary replace the crankshaft. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Bearing Installation > Page 1355 Plastigage Measurement 1. Remove oil from journal and bearing shell. 2. Install crankshaft. 3. Cut plastigage to same length as width of the bearing and place it in parallel with the journal axis. CAUTION: Do not rotate crankshaft or the plastigage will be smeared. 4. Install the main bearing cap carefully and tighten the bolts to specified torque. 5. Carefully remove the bearing cap and measure the width of the plastigage at the widest part using the scale on the plastigage package. 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 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Bearing Installation > Page 1356 being checked to the proper specifications. 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Dimensions Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Dimensions > Page 1361 Crankshaft: Specifications Crankshaft Main Bearing Caps 69 ft.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1362 Crankshaft: Description and Operation CONSTRUCTION The crankshaft is made of nodular cast iron and has six individual throws with five counter weights, it is supported by four main bearings with number three being the thrust bearing. VIBRATION CONTROL The six separate connecting rod throws pins reduce torque fluctuations while a dynamic damper is used to control torsional vibration of the crankshaft. SEAL LOCATIONS Rubber lipped seals are used at front and rear. The front seal is retained in the oil pump case and the rear is retained in a die cast aluminum block-mounted housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation Crankshaft: Service and Repair Removal and Installation GENERAL INFORMATION The crankshaft is supported in four main bearings. All upper bearing shells in the crankcase have oil grooves. All lower bearing shells in stalled in the monoblock main bearing cap are plain. Crankshaft end play is controlled by thrust washers on the number three main bearing journal. REMOVAL 1. Remove front mounted oil pump assembly and gasket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1365 2. Remove rear oil seal retainer and seal as assembly. 3. Release monoblock main bearing cap bolts evenly. Remove lower bearing shells and identify for reassembly. 4. Lift out crankshaft and remove upper thrust washers from each side of number three main bearing in the crankcase. INSTALLATION 1. Install upper main bearing shells making certain oil holes are in alignment, and bearing tabs seat in block tabs. All upper bearings have oil grooves. 2. THRUST BEARINGS. Crankshaft thrust bearings (washers) are installed at journal #3 separately from the radial bearings. Thrust bearings are different, one has end positioning tabs, while the other is plain. One pair of each thrust washers are installed into the block and one pair into the main bearing cap. 3. Apply a thin film of grease to plain side of thrust washers and position them on each side of number three main bearing. Grooved surface towards crankshaft. 4. Oil the bearings and journals and install crankshaft. 5. Install lower main bearing shells without oil grooves in monoblock cap. 6. Install one pair of thrust washers in cap. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1366 7. Carefully install bearing cap with arrows toward timing belt end. 8. Oil the bearing cap bolt threads, install and tighten bolts progressively in sequence shown to 94 Nm (69 ft. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1367 Crankshaft: Service and Repair Service Procedures END PLAY 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. Refer to specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation The heater, operated by ordinary house current (110 Volt A.C.) through a power cord and connector behind the radiator grille, 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. NOTE: The power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds and become damaged. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1371 Engine Block Heater: Testing and Inspection If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110volt test light; test heater element continuity with an ohmmeter or 12-volt test light. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1372 Engine Block Heater: Service and Repair REMOVAL 1. Drain coolant from radiator and cylinder block. 2. Detach 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 electrical connector position at the top of the core hole. 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. NOTE: The power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds and become damaged. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Core Plug <--> [Expansion/Freeze Plug] > Component Information > Service and Repair Core 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Crankshaft Pulley Crankshaft Damper: Specifications Chrankshaft Pulley Chrankshaft Pulley Torque Specification 182 Nm (134 ft.lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Crankshaft Pulley > Page 1380 Crankshaft Damper: Specifications Harmonic Balancer/Vibration Damper Bolt ...................................................................................................................................................... ................................................. 182 Nm (134 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 1381 Crankshaft Damper: Service and Repair 1. Remove drive belt splash shield. 2. Remove accessory drive belts. 3. Remove crankshaft center bolt and remove crankshaft damper. 4. Reverse Procedure for Installation and torque bolt to 182 Nm (134 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 1382 Puller 1026 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications O.D ...................................................................................................................................................... ............................................... 83.5 mm (3.29 inches) Piston to Cylinder Clearance ..................................................................................................................................... 0.02 - 0.04 mm (0.0008 - 0.0016 inch) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1386 Piston: Description and Operation Are aluminum alloy with cast in steel struts at the pin bosses for autothermic control. The piston head is designed with valve recesses to provide for valve clearance. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 REMOVAL 1. Identify pistons with matching cylinder. The pistons are not interchangeable from bank to bank. Pistons with the letter R and arrow toward the front of engine are to be installed in cylinders 1-3-5. Pistons with the letter L and arrow toward the front of engine are to be installed in cylinders 2-4-6. 2. Mark connecting rod and cap with cylinder number. 3. Remove piston rings. 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 with oil ring rail gap. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1389 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. 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. Install the piston and connecting rod assembly with the directional letter is located on the top of the piston with the arrow facing toward the camshaft sprocket. 7. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 51 Nm (37 ft. lb.). CAUTION: Piston assemblies are not to be interchanged from bank to bank. 9. Check alignment marks made during disassembly and that bearing position notches new or used are on the same side as shown. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1390 Piston: Service and Repair Fitting Pistons 1. Examine cylinder walls for scuffs, scoring and measure cylinder bore for out-of-round or taper. Measure at points shown. 2. Check clearance between piston and cylinder, clearance should be 0.02 - 0.04 mm (0.0008 - 0 0016 inch). 3. Measure approximately 2 mm (0.080 inch) above the bottom of the piston skirt and across the thrust face. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Description and Operation Piston Pin: Description and Operation Piston pins are press-fitted into place, to join the pistons to the forged steel connecting rods. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications END GAP: No.1 ..................................................................................................................................................... ...................... 0.25 - 0.40 mm (0.010 - 0.016 inch) Service Limit ........................................................ ............................................................................................................................. 0.8 mm (.031 inch) No. 2 .................................................................................................................................................... ...................... 0.40 - 0.55 mm (0.016 - 0.022 inch) Service Limit ........................................................ ............................................................................................................................. 0.8 mm (0.031 inch) Oil ........................................................................................................................................................ ..................... 0.15 - 0.50 mm (0.006 - 0.019 inch) Service Limit ......................................................... ............................................................................................................................ 1.0 mm (0.039 inch) SIDE CLEARANCE: No.1 ..................................................................................................................................................... .............. 0.030 - 0.070 mm (0.0012 - 0.0028 inch) Service Limit ........................................................ ............................................................................................................................. 0.1 mm (0.004 inch) No.2 ..................................................................................................................................................... .............. 0.002 - 0.060 mm (0.0007 - 0.0024 inch) Service Limit ........................................................ ............................................................................................................................. 0.1 mm (0.004 inch) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1397 Piston Ring: Description and Operation The piston rings consist of a chrome-plated, barrel faced design for the top ring, the second ring is a cast iron tapered face design and the oil ring is a chrome faced three piece design. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Fitting Piston Rings Piston Ring: Service and Repair Fitting Piston Rings END GAP CLEARANCE 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 16 mm (0.63 inch) from bottom of cylinder bore. Check gap with feeler gauge. SIDE GROOVE CLEARANCE Check piston ring to groove clearance. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Fitting Piston Rings > Page 1400 Piston Ring: Service and Repair Installation 1. The No. 1 and No. 2 piston rings have a different cross section. Install rings with manufacturers mark and size mark facing up, to the top of the piston . CAUTION: Install piston rings in the following order: a. Oil ring expander. b. Upper oil ring side rail. c. Lower oil ring side rail. d. No. 2 Intermediate piston ring. e. No. 1 Upper piston ring. 2. Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do Not use a piston ring expander. 3. Install upper side rail first and then the lower side rail. 4. Install No. 2 piston ring and then No. 1 piston ring. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Fitting Piston Rings > Page 1401 5. Position piston ring end gaps as shown. 6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1409 Fuel Pressure Release: Service and Repair Fig. 2 Releasing Fuel Pressure Fig. 1 Fuel Pressure Test Port--Typical CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock. 1. Disconnect the fuel rail electrical harness from the engine harness. Refer to Diagrams/Electrical. 2. Connect one end of a jumper wire to the A142 circuit terminal of the fuel rail harness connector. 3. Connect the other end of the jumper wire to a 12 volt power source. 4. Connect one end of a jumper wire to a good ground source. 5. Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector. Repeat procedure for 2 to 3 injectors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 31 Nm (23 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm Assembly Rocker Arm Assembly: Description and Operation Rocker Arm Assembly Are of light weight die-cast with roller type follower operating against the camshaft. The valve actuating end of the rocker arms are machined for hydraulic lash adjusters, eliminating the need for periodic valve lash adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation > Rocker Arm Assembly > Page 1415 Rocker Arm Assembly: Description and Operation Rocker Arm Shaft GENERAL INFORMATION The shafts are retained by retaining caps and bolts. Four shafts are used, one for each intake and exhaust rocker arm assembly on each cylinder head. The hollow shafts provide a duct for lubricating oil flow from the cylinder head to the valve mechanisms. SHAFT SPRINGS Rocker shaft springs are used on the intake shafts ONLY to obtain the proper clearance between the intake rocker arms and the spark plug tubes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement Rocker Arm Assembly: Service and Repair Rocker Arm Replacement REMOVAL 1. Remove cylinder head cover. 2. Identify the rocker arm shaft assemblies before removal. 3. Install auto lash adjuster retainers, Special Tool MD-998443, or equivalent onto rocker arms. These retainers hold the lash adjusters into position when the rocker arms are serviced. 4. Loosen the attaching fasteners. Remove rocker arm shaft assemblies from cylinder head. 5. Mark rocker arm/hydraulic lash adjuster assemblies for reassembly in their original position. Remove rocker arm/hydraulic lash adjuster assembly. Lash adjusters are serviced as an assembly with the rocker arm. NOTE: The automatic lash adjusters are precision units installed in machined openings in the valve actuating ends of the rocker arms. Do not disassemble the auto lash aid. INSTALLATION Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement > Page 1418 1. Install rocker arm and shafts with the FLAT on the shafts facing the timing belt side of the right cylinder head. For the left cylinder head, install rocker arm and shafts with the FLAT on the shafts facing the transmission side of the engine. Install the retainers and spring clips in their original positions on the exhaust and intake shafts. 2. Tighten bolts to 31 Nm (276 in. lbs.) in sequence shown. 3. Remove auto lash adjuster retainers Special Tool MD-998443, or equivalent from rocker arms. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Rocker Arm Replacement > Page 1419 Rocker Arm Assembly: Service and Repair Inspection Rocker Arm Assembly Inspect the rocker arm/hydraulic lash adjuster assembly for wear or damage. Replace assembly as necessary. Rocker Arm Shaft The rocker arm shafts is hollow and is used as a lubrication oil duct. 1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if damaged or worn. 2. Check oil holes for clogging with small wire, clean as required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1420 Holders MD-998443 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Cylinder Head Cover Bolts 9.9Nm. (88 in. lb.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal and Installation Valve Cover: Service and Repair Removal and Installation REMOVAL 1. Remove air intake plenum. 2. Cover lower intake manifold with a suitable cover during service. 3. Disconnect and relocate spark plug wires. 4. Remove cylinder head cover screws and remove cover. NOTE: Before installation, clean cylinder head and cover mating surfaces. Make certain the rails are flat. INSTALLATION 1. Clean cylinder head and cover mating surfaces. Install new gasket. 2. Install cover and tighten cover bolt washer and gasket assembly to 3.5 Nm (2.5 inch lbs.). SPARK PLUG TUBE SEALS The spark plug tube seals are located on the end of each tube. These seals slide onto each tube to seal the cylinder head cover to spark plug tube. If these seals show signs of hardness and/or cracks they should be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Removal and Installation > Page 1426 Valve Cover: Service and Repair Cleaning and Inspection Before installation, clean cylinder head and cover mating surfaces. Make certain the rails are flat. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1430 Valve Guide: Description and Operation Valve guides are made of cast iron alloy. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1431 Valve Guide: Service and Repair 1. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 2. Using a small hole gauge and a micrometer, measure valve guides in 3 places top, middle and bottom. Refer to specifications. Replace guides if they are not within specification. 3. Check valve guide height. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Description and Operation Valve Seat: Description and Operation Seat inserts are made of sintered alloy iron, these are pressed into the head. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Description and Operation > Page 1435 Valve Seat: Service and Repair Inspect the valve seat with 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 the valve face, lower valve seat with a 15 degrees stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degree stone. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off Valve Spring: Service and Repair Cylinder Head Off REMOVAL 1. With valve spring compressor Special Tool C-3422B with adapter 6526, or equivalents. Remove spring retainer locks, retainer, valve spring, and valve. 2. Remove valve stem seals with suitable tool. Do not reuse valve stem seals. INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install valve spring seat. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1441 3. Install the silver valve seal onto the intake valve guide and the black seal onto the exhaust value guide. Using Special Tool MD-998774, or equivalent install seal by tapping lightly until seal is in place. 4. Install valve spring with the enamelled ends facing the rocker arms. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1442 Valve Spring: Service and Repair Cylinder Head On REMOVAL 1. Remove rocker arm shafts assemblies. 2. Rotate crankshaft until piston is at Top Dead Center (TDC) on compression. 3. With air hose attached to adapter tool installed in spark plug hole, apply 90 - 120 psi air pressure. 4. Use Special Tool MD-998772A with Mounting Post 6886, Forcing Screw Arm 6887, Forcing Screw 6765 and adapter 6865, or equivalents to compress valve springs and remove valve locks. 5. Remove valve spring. 6. Remove valve stem seal by using a valve stem seal tool. INSTALLATION 1. Install valve seal. 2. Use Special Tool MD-998772A with Mounting Post 6886, Forcing Screw Arm 6887, Forcing Screw 6765 and adapter 6865, or equivalents to compress valve springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems (air pressure required), piston at TDC. 3. Install rocker arm and lash adjuster assemblies. 4. Install cylinder head cover. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1443 Valve Spring: Service and Repair Inspection Measure Valve spring free length and if the spring is square. Refer to specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1444 Valve Spring: Tools and Equipment Valve Spring Compressor MD-998772-A Spring Compressor Adapter 6779 Compressor C-3422-B Adapter 6526 Screw 6765 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1445 Adapter 6885 Posts 6886 Adapter 6887 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1449 Valve: Description and Operation GENERAL INFORMATION Four valves per cylinder are actuated by die-cast aluminum roller rocker arms and hydraulic lash adjusters assemblies which pivot on rocker armed shafts. DIMENSIONS All valves have 6 mm diameter chrome plated valve stems. The valve train has 33 mm (1.299 inch) diameter intake valves and 29 mm (1.141 inch) diameter exhaust valves. FINISH The valves have a carbon-nitriding finish for long life. SEAL TYPE Fluorocarbon valve stem seals are used on both valves. COMPONENTS Stamped steel valve spring seat, Valve springs, spring retainers, and locks are conventional. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1450 Valve: Testing and Inspection 1. Check valve stem tip for pitting or depression at point A. 2. Check for wear and ridge wear at Point B. 3. Measure the clearance between the valve guide and valve stem. If the service limit is exceeded, replace the valve guides, valves or both. 4. Check for even contact (at face center) with valve seat, Point C. 5. Check margin. Replace valve if margin is out of specification. 6. Check valve guide height. 7. Measure valve stem to guide clearance. Refer to specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1451 Valve: Service and Repair REMOVAL 1. With valve spring compressor Special Tool C-3422B with adapter 6526, or equivalents. Remove spring retainer locks, retainer, valve spring, and valve. 2. Remove valve stem seals with suitable tool. Do not reuse valve stem seals. INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install valve spring seat. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1452 3. Install the silver valve seal onto the intake valve guide and the black seal onto the exhaust value guide. Using Special Tool MD-998774, or equivalent install seal by tapping lightly until seal is in place. 4. Install valve spring with the enamelled ends facing the rocker arms. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > A/C Belt Tension Drive Belt: Specifications A/C Belt Tension New ..................................................................................................................................................... ...................................................................... 150 lbs. Used .................................................................................................................................................... ......................................................................... 80 lbs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > A/C Belt Tension > Page 1458 Drive Belt: Specifications Alternator Belt Tension New ..................................................................................................................................................... ...................................................................... 150 lbs. Used .................................................................................................................................................... ......................................................................... 80 lbs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > A/C Belt Tension > Page 1459 Drive Belt: Specifications Power Steering Belt Tension New ..................................................................................................................................................... ...................................................................... 130 lbs. Used .................................................................................................................................................... ......................................................................... 80 lbs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1460 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1461 Drive Belt: Description and Operation The engine is equipped with 2 drive belts. One belt drives the power steering pump, the other drives the generator and air conditioning. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1462 Drive Belt: Testing and Inspection Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment Drive Belt: Adjustments A/C Belt Adjustment To adjust the air conditioning and generator drive belt, loosen the idler pulley bolt and adjust belt tension by turning adjusting screw. Tighten pulley bolt to 54 Nm (40 ft. lbs.) after adjustment. For conventional belts and Poly-V belts, use belt tensioning Special Tool Kit C-4162 to obtain proper belt tension. Adjust the belt tension for a New or Used belt as prescribed in specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment > Page 1465 Drive Belt: Adjustments Alternator Belt Adjustment To adjust the air conditioning and generator drive belt, loosen the idler pulley bolt and adjust belt tension by turning adjusting screw. Tighten pulley bolt to 54 Nm (40 ft. lbs.) after adjustment. For conventional belts and Poly-V belts, use belt tensioning Special Tool Kit C-4162 to obtain proper belt tension. Adjust the belt tension for a New or Used belt as prescribed in specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Adjustments > A/C Belt Adjustment > Page 1466 Drive Belt: Adjustments Power Steering Pump Belt Adjustment For conventional belts and Poly-V belts, use belt tensioning Special Tool Kit C-4162 to obtain proper belt tension. Adjust the belt tension for a New or Used belt as prescribed in specifications. 1. From the top of the vehicle loosen pivot bolt. 2. From under the vehicle loosen the locking bolts D and E. 3. Adjust belt tension with 1/2 inch breaker bar installed in adjusting bracket. 4. Tighten locking bolt E to 28 Nm (250 inch lbs.). 5. Tighten locking bolt D and the pivot bolt to 54 Nm (40 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt Drive Belt: Service and Repair A/C Belt To remove and install the air conditioning compressor and generator drive belt, first loosen the idler pulley lock bolt, then turn the adjusting screw to increase or decrease the idler pulley tension. To adjust the air conditioning and generator drive belt, loosen the idler pulley bolt and adjust belt tension by turning adjusting screw. Tighten pulley bolt to 54 Nm (40 ft. lbs.) after adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1469 Drive Belt: Service and Repair Alternator Belt To remove and install the air conditioning compressor and generator drive belt, first loosen the idler pulley lock bolt, then turn the adjusting screw to increase or decrease the idler pulley tension. To adjust the air conditioning and generator drive belt, loosen the idler pulley bolt and adjust belt tension by turning adjusting screw. Tighten pulley bolt to 54 Nm (40 ft. lbs.) after adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C Belt > Page 1470 Drive Belt: Service and Repair Power Steering Belt 1. From the top of the vehicle loosen pivot bolt. 2. From under the vehicle loosen the locking bolts D and E. 3. Install the belt. Adjust belt tension with 1/2 inch breaker bar installed in adjusting bracket. 4. Tighten locking bolt E to 28 Nm (250 inch lbs.). 5. Tighten locking bolt D and the pivot bolt to 54 Nm (40 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Page 1471 Belt Tension Gauge C-4162 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Auto Tensioner Bolt ............................................................................................................................. .................................................... 23 Nm (17 ft. lbs.) Pulley Bolt ......................................................... ....................................................................................................................................... 48 Nm (35 ft. lbs.) Tensioner Arm Assembly Bolt ..................................................................................................... ............................................................ 44 Nm (33 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Bracket Bolts ....................................................................................................................................... ..................................................... 45 Nm (33 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1478 Engine Mount: Adjustments GENERAL INFORMATION The right and left support assemblies are slotted to allow for right/left drive train adjustment in relation to drive shaft assembly length. Check and reposition right and left engine support assemblies as required. Adjust drive train position, if required, for the following conditions: ^ Drive shaft distress. ^ Any front end structural damage (after repair). ^ Support Assembly replacement. ADJUSTMENT 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 support assembly vertical fasteners. 3. Loosen the left engine support assembly vertical bolts. 4. Pry the engine right or left as required to achieve the proper drive shaft assembly length. 5. Tighten right engine support assembly vertical bolts to 61 Nm (45 ft. lbs.) and tighten left engine support assembly bolts to 61 Nm (45 ft. lbs.). 6. Recheck drive shaft length. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Support Module (Front and Rear Mounts) Engine Mount: Service and Repair Engine Support Module (Front and Rear Mounts) REMOVAL 1. Raise vehicle on hoist. 2. Remove thru bolt at rear mount and remove bolts attaching module to crossmember. 3. Remove upper attaching bolt from rear support strut bracket. 4. Remove front attaching bolts from support module to lower radiator support. 5. Support cooling module. 6. Remove lower radiator support bolts, and remove support. 7. Remove thru bolt at front mount and remove support module. INSTALLATION 1. Install thru bolt at front mount. Do not tighten at this time. 2. Install lower radiator support. 3. Install attaching bolts from support module to lower radiator support. 4. Install upper bolt at rear support strut bracket. 5. Install thru bolt at rear mount and tighten to 61 Nm (45 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Support Module (Front and Rear Mounts) > Page 1481 6. Tighten thru bolt at front mount and tighten to 61 Nm (45 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Support Module (Front and Rear Mounts) > Page 1482 Engine Mount: Service and Repair Left Mount NOTE: ^ If centering or adjusting the engine/transmission assembly is needed refer to Adjustments. ^ The left side engine mount is a Hydro-Mount and may show surface cracks this will not effect it's performance and should not be replaced. Only replace the Hydro-Mount when it's leaking fluid. 1. Support the transmission with a transmission jack. 2. Remove the three vertical bolts, from the mount to the transmission. 3. Remove the transmission mount fasteners and remove mount. 4. Reverse removal procedure for installation. Noting bolt specifications. 5. Perform engine support assemblies adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Support Module (Front and Rear Mounts) > Page 1483 Engine Mount: Service and Repair Right/Engine Support Bracket NOTE: The right side engine mount is a Hydro-Mount and may show surface cracks this will not effect it's performance and should not be replaced. Only replace the Hydro-Mount when it's leaking fluid. 1. Raise vehicle on a hoist and remove inner splash shield. Remove the right engine support assembly vertical fasteners from frame rail. 2. Lower vehicle. Remove the load on the engine motor mounts by carefully supporting the engine assembly with a floor jack. 3. Remove the three bolts attaching the engine support assembly to the engine bracket. 4. Move the air conditioning dryer aside. 5. Remove coolant recovery system tank. Refer to Cooling System for procedure. 6. Remove right engine support. 7. Remove the three bolts attaching the engine support bracket to the cylinder block. NOTE: If centering or adjusting the engine/transmission assembly is needed refer to Adjustments. 8. Reverse removal procedure for installation. Noting bolt specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Bolt ...................................................................................................................................................... ..................................................... 44 Nm (33 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications At Curb Idle Speed .............................................................................................................................. ............................................................ 41 kPa (6 psi) At 3000 rpm ..................................................... ........................................................................................................................... 241 - 515 kPa (35 75 psi) CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1491 Engine Oil Pressure: Testing and Inspection GENERAL INFORMATION Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 41 kPa (6 psi) at idle or 241 - 517 kPa (35 - 75 psi) at 3000 RPM. PROCEDURE 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications To Oil Pan ............................................................................................................................................ .................................................... 40 Nm (29 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.3L (4.5 Qt) Without Filter Change ....................................... ................................................................................................................................................ 3.8L (4.0 Qt) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1499 Engine Oil: Fluid Type Specifications Engine Oil API Classification .............................................................................................................................................................. SJ ECII or SJ/CD ECII or Above Above 0°F (-18°C)............................................................................ .......................................................................................................................... 10W-30 Below 100°F (38°C)................................................................................................................................................... .................................................. 5W-30 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Technician Safety Information > Page 1502 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1503 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1504 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service Precautions > Page 1505 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications To Adapter ........................................................................................................................................... ..................................................... 14 Nm (10 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1509 Oil Filter: Description and Operation All engines are equipped with a high quality full flow, disposable type oil filter. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1510 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 lockseam. The lockseam joining the can to the base is reinforced by the base plate. 1. Turn counter clockwise to remove. 2. To install, lubricate new filter gasket. Screw filter on until gasket contacts base. Tighten to 14 Nm (10 ft.lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Mounting Bolt ....................................................................................................................................... ................................................... 23 Nm (17 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 1514 Oil Filter Adapter: Service and Repair 1. Check the oil filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. 2. Check bracket for cracks and oil leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications To Block Bolts ...................................................................................................................................... ........................................................ 6 Nm (4 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1518 Oil Pan: Service and Repair REMOVAL 1. Disconnect battery negative remote cable. 2. Remove oil drain plug and drain oil. 3. Remove engine support module. 4. Remove dipstick tube. 5. Remove starter motor. 6. Remove engine to transaxle struts. 7. Remove transaxle inspection cover. 8. Remove oil pan. NOTE: Oil pan to cylinder block sealing is provided with Mopar Silicone Rubber Adhesive Sealant or equivalent gasket material. INSTALLATION 1. Apply sealant as shown. 2. Install pan and tighten screws to 6 Nm (50 inch lbs.). 3. Reverse removal procedure for installation. 4. Install correct Amount of new oil. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to alert the operator that engine oil pressure has dropped below a predetermined pressure. The oil pressure switch uses a switch that CLOSES when the pressure is below the predetermined level. The switch is case grounded to the engine block. Power for the lamp is supplied on the F15 circuit. This circuit also powers the Anti-Lock lamp, located internal to the cluster, high speed fan relay, A/C Clutch relay, and the Powertrain Control Module (PCM). This circuit is protected by a 10 amp fuse located in cavity 9 of the Power Distribution Center (PDC). The ground side of the lamp is controlled by the G6 circuit. This circuit is connected from the instrument cluster to the engine oil pressure switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Bolts ..................................................................................................................................................... ...................................................... 10 Nm (7 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Screen Bolt .......................................................................................................................................... ..................................................... 19 Nm (13 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications At Curb Idle Speed .............................................................................................................................. ............................................................ 41 kPa (6 psi) At 3000 rpm ..................................................... ........................................................................................................................... 241 - 515 kPa (35 75 psi) CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1535 Engine Oil Pressure: Testing and Inspection GENERAL INFORMATION Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 41 kPa (6 psi) at idle or 241 - 517 kPa (35 - 75 psi) at 3000 RPM. PROCEDURE 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Specifications > Mechanical Specifications Oil Pressure Regulator Valve: Mechanical Specifications Relief Plug ........................................................................................................................................... ..................................................... 44 Nm (33 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Specifications > Mechanical Specifications > Page 1540 Oil Pressure Regulator Valve: Pressure, Vacuum and Temperature Specifications Opening Pressure ........................................................................................................................................................... 5.0 - 6.0 kg/cm2 (71.45 - 85.75 psi) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Aluminum Engine - Gasket Surface Preparation Intake Manifold: Technical Service Bulletins Aluminum Engine - Gasket Surface Preparation NO: 09-09-97 GROUP: Engine DATE: Dec. 19, 1997 SUBJECT: Gasket Surface Preparation On Aluminum Engine Components MODELS: 1995 (AA) Acclaim/Spirit 1995 (AJ) Lebaron Convertible 1995 (AS) Caravan/Voyager/Town & Country 1995 - 1998 (FJ) Avenger/Sebring/Talon 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1995 - 1998 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1996 - 1998 (NS) Caravan/Voyager/Town & Country 1995 - 1998 (PL) Neon 1997 (PR) Prowler DISCUSSION: Many aluminum engine components are being received by the material return center with gouges, scratches, and out of flat conditions on the sealing surface. Caution must be exercised when cleaning aluminum engine components. The use of solvents and plastic or wooden scrapers are the only approved methods for removing gasket material. NOTE: DO NOT USE METAL SCRAPERS GRINDING DISCS OR ABRASIVES TO CLEAN ALUMINUM ENGINE COMPONENTS. DAMAGE TO THE SEALING SURFACE WILL OCCUR. Engine components received by the material return center will be evaluated for appropriate gasket removal procedures. Components returned with obvious damage caused by improper gasket removal procedures may be denied for warranty reimbursement. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Mechanical Specifications Intake Manifold: Mechanical Specifications General Specifications Manifold Flatness Intake ................................................................................................................................................... ............................................ 0.10 mm (0.004 inch) Service Limit ........................................................ ............................................................................................................................. 0.2 mm (0.008 inch) Torque Specifications Plenum Bolt ......................................................................................................................................... ................................................ 18 Nm (160 inch lbs.) Plenum Support Bolt M8 ................................................................................................................................................ ........................................... 18 Nm (160 inch lbs.) Bolt M10 ............................................................... ............................................................................................................................ 36 Nm (26.5 ft. lbs.) Intake Manifold Nut .............................................................................................................................. .............................................. 21 Nm (186 inch lbs.) Intake Manifold Lower Fasteners ........................................................................................................................................................ 21 Nm (185 inch lbs.) Intake Manifold Upper Plenum Bolts .................................................................................................................................................. 18 Nm (160 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Mechanical Specifications > Page 1547 Intake Manifold: Pressure, Vacuum and Temperature Specifications Minimum Vacuum ................................................................................................................................ ................................................. 60 kPa (18 inch Hg) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1548 Intake Manifold: Description and Operation GENERAL INFORMATION This system is composed of a upper plenum (surge tank) and lower manifold. This aluminum alloy manifold has long runners to improve inertia. PLENUM CHAMBER PURPOSE The plenum chamber (surge tank) absorbs air pulsations created during the suction phase of each cylinder. LOWER INTAKE MANIFOLD PURPOSE The lower intake manifold is machined for six injectors and fuel rail mounting. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1549 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection Intake Manifold: Service and Repair Cleaning and Inspection 1. Discard gasket and clean all gasket surfaces of manifold to cylinder heads. 2. Check upper and lower manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 inch per foot) of manifold length. 3. Inspect manifolds for cracks or distortion. Replace manifold if necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1552 Intake Manifold: Service and Repair Intake Manifold Replacement Removal 1. Disconnect negative cable from auxiliary jumper terminal. WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. 2. Release fuel system pressure. CAUTION: Wrap shop towels around hose to catch any gasoline spillage. 3. Disconnect fuel supply tube from rail. 4. Unplug connectors from Manifold Absolute Pressure (MAP) and intake air temperature sensors. 5. Remove plenum support bracket bolt located rearward of MAP sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1553 6. Remove bolt holding air inlet resonator to intake manifold. 7. Loosen throttle body air inlet hose clamp. 8. Release snaps holding air cleaner housing cover to housing. 9. Remove air cleaner cover and inlet hoses from engine. 10. Unplug Throttle Position Sensor (TPS) and idle air control motor connectors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1554 11. Squeeze retainer tab on throttle cable and slide cable out of bracket. 12. Slide Speed control cable out of bracket, if equipped. 13. Remove EGR tube from intake manifold. 14. Remove plenum support bracket bolt located rearward of EGR tube. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1555 15. Remove 7 bolts holding upper intake plenum and remove plenum. 16. Disconnect electrical connectors from fuel injectors. 17. Remove 4 bolts holding fuel rail. 18. Lift fuel rail off engine. There are spacers under each fuel rail bolt. 19. Remove lower intake manifold attaching bolts. Remove intake manifold. Installation 1. Install intake manifold with new gaskets. Tighten in sequence shown to 21 Nm (185 inch lbs.). 2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector. 3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 Nm (8 ft. lbs.). 4. Attach electrical connectors to fuel injectors. 5. Connect fuel supply tube to fuel rail. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1556 6. Install new gasket and position upper intake plenum. Tighten plenum bolts to 18 Nm (13 ft. lbs.) torque. 7. Install bolts at plenum support brackets. Tighten bolts to 18 Nm (13 ft. lbs.). 8. Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 inch lbs) torque. 9. Install throttle cables. 10. Attach electrical connectors to sensors. 11. Tighten air inlet tube clamps to 3 Nm ±1 (25 inch lbs. ±5). 12. Connect negative terminal to terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to alert the operator that engine oil pressure has dropped below a predetermined pressure. The oil pressure switch uses a switch that CLOSES when the pressure is below the predetermined level. The switch is case grounded to the engine block. Power for the lamp is supplied on the F15 circuit. This circuit also powers the Anti-Lock lamp, located internal to the cluster, high speed fan relay, A/C Clutch relay, and the Powertrain Control Module (PCM). This circuit is protected by a 10 amp fuse located in cavity 9 of the Power Distribution Center (PDC). The ground side of the lamp is controlled by the G6 circuit. This circuit is connected from the instrument cluster to the engine oil pressure switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Front Cam Seal Retainer - New Design Camshaft Oil Seal: Technical Service Bulletins Front Cam Seal Retainer - New Design NUMBER: 09-008-00 GROUP: Engine DATE: Jan. 12, 2001 SUBJECT: Front Cam Seal Retention OVERVIEW: This bulletin involves installation of a new component to assist cam seal retention. MODELS: NOTE: THIS INFORMATION APPLIES TO MODELS EQUIPPED WITH A 1.8 OR 2.0L SOHC ENGINE. DISCUSSION: A new cam seal retainer has been released to retain the front cam seal on 1.8L or 2.0L SOHC engines. Whenever a cam seal is replaced, a retainer should be installed to provide positive retention. PARTS REQUIRED: REPAIR PROCEDURE: 1. Upon engine re-assembly after front cam seal installation, install the retainer p/n 5016733AA using the inner cover fasteners as shown in (Fig. 1) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Front Cam Seal Retainer - New Design > Page 1566 2. Torque the fasteners to 20 Nm (15 ft. lbs.). 3. Complete the re-assembly following the applicable service manual. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Page 1567 Camshaft Oil Seal: Service and Repair 1. Apply light coat of engine oil to the camshaft oil seal lip. 2. Install the oil seal using Special Tool MD998713 or 6863, or equivalent camshaft oil seal installers. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Page 1568 Camshaft Oil Seal: Tools and Equipment Camshaft Seal Remover C-4679-A Installer MD-998718 Camshaft Seal Installer 6863 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Specifications Rear Crankshaft Seal: Specifications Retainer Bolt ........................................................................................................................................ ....................................................... 11 Nm (8 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Specifications > Page 1572 Rear Crankshaft 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Specifications > Page 1573 Rear Crankshaft Seal: Service and Repair REMOVAL Rear Seal Assembly 1. Remove rear oil seal retainer and seal as assembly 2. Release monoblock main bearing cap bolts evenly. Remove lower bearing shells and identify for reassembly. 3. Lift out crankshaft and remove upper thrust washers from each side of number three main bearing in the crankcase. INSTALLATION 1. Install rear crankshaft oil seal in housing with Special Tool MD998718, or equivalent. 2. Apply Mopar Silicone Rubber Adhesive Sealant or equivalent to oil seal housing. 3. Apply light coating of engine oil to the entire circumference of oil seal lip. 4. Install seal assembly on cylinder block and tighten bolts to 11 Nm (96 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Specifications > Page 1574 Installer MD-998718 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Head Gasket - Application Cylinder Head Gasket: Technical Service Bulletins Head Gasket - Application NUMBER: 09-07-99 GROUP: Engine DATE: Sep. 17, 1999 SUBJECT: 2.5L V-6 Head Gasket Application MODELS: 1995 - 2000 (FJ) Avenger/Sebring 1995 - 2000 (JA) Cirrus/Stratus/Breeze 1996 - 2000 (JX) Sebring Convertible NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.5L V-6 ENGINE. DISCUSSION: Changes were made to 2.5L V-6 engines beginning in the 1998 model year. These changes included a new head gasket (Steel) and accompanying piston changes to compensate for the reduced clearance. When replacing head gaskets or pistons, it is important to select part numbers for the appropriate year of vehicle/engine that is being serviced. The part numbers are appropriately identified in the parts catalog and PAIS system. If a composite gasket was originally on the engine (1995/1996/1997), a composite gasket must be used as a replacement gasket. CAUTION: ENGINES ORIGINALLY BUILT WITH A COMPOSITE HEAD GASKET MUST USE A COMPOSITE GASKET AS A REPLACEMENT PART. ENGINE DAMAGE WILL OCCUR IF A COMPOSITE GASKET IS REPLACED WITH A STEEL GASKET. POLICY: Information Only. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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. Remove crankshaft damper. 2. Remove timing belt. 3. Remove crankshaft sprocket and key. 4. Pry out the front seal with a flat tip screwdriver. Cover the end of the screwdriver with a shop towel. CAUTION: Be careful not to nick or damage crankshaft flange surface or oil pump housing bore. INSTALLATION 1. Install front crankshaft seal into oil pump housing using Special Tool MD-998717, or equivalent. 2. Reverse removal procedure for installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1582 Installer MD-998717 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Application and ID Valve Guide Seal: Application and ID ^ Silver valve seal is used for the intake valve guide ^ Black valve seal is used for the exhaust value guide Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Application and ID > Page 1586 Valve Guide Seal: Description and Operation Fluorocarbon valve stem seals are used on both valves. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off Valve Guide Seal: Service and Repair Cylinder Head Off REMOVAL 1. With valve spring compressor Special Tool C-3422B with adapter 6526, or equivalents. Remove spring retainer locks, retainer, valve spring, and valve. 2. Remove valve stem seals with suitable tool. Do not reuse valve stem seals. INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install valve spring seat. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off > Page 1589 3. Install the silver valve seal onto the intake valve guide and the black seal onto the exhaust value guide. Using Special Tool MD-998774, or equivalent install seal by tapping lightly until seal is in place. 4. Install valve spring with the enamelled ends facing the rocker arms. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off > Page 1590 Valve Guide Seal: Service and Repair Cylinder Head On REMOVAL 1. Remove rocker arm shafts assemblies. 2. Rotate crankshaft until piston is at Top Dead Center (TDC) on compression. 3. With air hose attached to adapter tool installed in spark plug hole, apply 90 - 120 psi air pressure. 4. Use Special Tool MD-998772A with Mounting Post 6886, Forcing Screw Arm 6887, Forcing Screw 6765 and adapter 6865, or equivalents to compress valve springs and remove valve locks. 5. Remove valve spring. 6. Remove valve stem seal by using a valve stem seal tool. INSTALLATION 1. Install valve seal. 2. Use Special Tool MD-998772A with Mounting Post 6886, Forcing Screw Arm 6887, Forcing Screw 6765 and adapter 6865, or equivalents to compress valve springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems (air pressure required), piston at TDC. 3. Install rocker arm and lash adjuster assemblies. 4. Install cylinder head cover. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1591 Installer MD-998774 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt 65 ft.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1600 Camshaft Gear/Sprocket: Service and Repair REMOVAL 1. Hold camshaft sprocket with Special Tool 6847, or equivalent loosen and remove bolt and washer. 2. Remove camshaft sprocket from camshaft. INSTALLATION 1. Place camshaft sprocket on camshaft. 2. Install bolt and washer to camshaft. Using Special Tool 6847, or equivalent hold camshaft sprocket and torque bolt to 88 Nm (65 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 1601 Holder 6847 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications Timing Belt: Specifications On 1995-97 Avenger & Sebring Coupe CA vehicles, replacement at 60,000 mile intervals is recommended but not required. On 1998-2000 Avenger & Sebring Coupe CA, CT & MS models, replacement at 60,000 mile intervals is recommended but not required. On all other Avenger & Sebring Coupe models, replace every 100,000 miles (if not previously replaced). On 1995-98 Cirrus, Sebring Convertible & Stratus models, replacement at 105,000 mile intervals is recommended but not required. On 1999 Sebring Convertible & 1999-2000 Cirrus & Stratus models, replace revery 105,000 miles or 84 months. On 2000 Sebring Convertible vehicles, replace every 105,000 miles or 84 months. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection Timing Belt: Service and Repair Cleaning and Inspection 1. Remove the upper left timing belt cover. 2. Inspect both sides of the timing belt drive & back. Replace belt if any of the following conditions exist. ^ Hardening of back rubber back side is glossy without resilience and leaves no indent when pressed with fingernail. ^ Cracks on rubber back. ^ Cracks or peeling of canvas. ^ Cracks on rib root. ^ Cracks on belt sides. ^ Missing teeth. ^ Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife. 3. If none of the above conditions are seen on the belt. the belt cover can be reinstalled. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 1607 Timing Belt: Service and Repair Timing Belt Removal and Installation For timing cover removal and installation, See: Timing Cover/Service and Repair REMOVAL 1. Mark belt running direction for installation. 2. Loosen timing belt auto tensioner bolts and remove timing belt. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 1608 INSTALLATION 1. Set crankshaft sprocket to Top Dead Center (TDC) by aligning the sprocket with the mark on the oil pump housing, then back off to 3 notches before TDC. 2. Set camshaft sprockets to the aligning marks on the sprockets with the marks on the rear timing belt cover. 3. Install timing belt on rear camshaft sprocket first and install a binder clip on the belt and sprocket so the belt will not slip out of position. Keeping the belt taught, install under the water pump pulley and then around the front camshaft sprocket. Install an additional binder clip on the front sprocket and belt. 4. Rotate the crankshaft to TDC. Continue routing the belt by the idler pulley and around the crankshaft sprocket to the tensioner Pulley 5. Apply rotating force to the crankshaft sprocket in the clockwise direction, to tension belt, check that all timing marks are aligned. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 1609 6. Using Special Tool MD 998767, or equivalent and a torque wrench on the tensioner pulley. Apply 4.4 Nm (38.9 inch lbs.) of torque to tensioner. Tighten tensioner pulley bolt to 48 Nm (35 ft. lbs.). 7. With torque being applied to the tensioner pulley install the tensioner to the tensioner pulley bracket and tighten fasteners to 23 Nm (205 inch lbs.). 8. Pull tensioner plunger pin. 9. Rotate crankshaft 2 revolutions in a clockwise direction ONLY and check the alignment of the timing marks. Install tensioner pin into assembly. The pin should slide in and out without any resistance. If the pin does not slide freely, perform the procedure again. 10. Install front half of timing cover and engine mount bracket. 11. Install right engine mount. 12. Remove jack from under engine. 13. Install crankshaft damper and crankshaft damper bolt and tighten to 182 Nm (134 ft. lbs.). 14. Install accessory drive belts. 15. Raise vehicle on hoist and install right inner splash shield. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 1610 Timing Belt: Service and Repair Camshaft and Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications Timing Belt Tensioner: Specifications Mounting Bolt ....................................................................................................................................... ................................................... 24 Nm (17 ft. lbs.) Pulley Bolt .......................................................... ...................................................................................................................................... 48 Nm (35 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications > Page 1614 Timing Belt Tensioner: Service and Repair 1. When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body. 2. Place the tensioner into a vise and slowly compress the plunger. NOTE: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine. 3. Compress plunger into the tensioner body. Install a pin through the body to retain the plunger. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications > Page 1615 Wrench MD-998767 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair REMOVAL 1. Remove right inner splash shield. 2. Remove the accessory drive belts. 3. Remove right engine mount. 4. Remove crankshaft damper. NOTE: To remove engine mount bracket the timing belt cover must be removed first. 5. Remove the engine mount bracket. 6. Remove the timing belt covers. Remove covers in this order: a. The upper left cover. b. The upper right cover. c. The lower cover. NOTE: To remove right/rear timing belt cover, the power steering pump bracket must be removed. 7. To install reverse previous procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Adapter Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 miles ................................................................................ .............................................................................................. 450 - 1,100 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 500 - 1,100 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1627 Idle Speed: Testing and Inspection Fig. 35 Purge Hose 1. Turn ignition key to Off. 2. Disconnect the PCV valve hose from the intake manifold nipple. Cap the PCV vacuum nipple. 3. Disconnect purge hose from the nipple on the throttle body Fig. 35. Fig. 37 Orifice6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) to the purge nipple on the throttle body Fig. 37. 5. Ensure that all accessories are off. 6. Connect the DRB Scan Tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB Scan Tool, access Minimum Airflow Idle Speed. 9. The following will then occur: - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB Scan Tool displays engine RPM 10. If idle RPM is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. - Below 1,000 miles ............................................................................................................................. ........................................... 450 - 1,100 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 500 - 1,100 rpm 11. If idle RPM is above specifications, use the DRB Scan Tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves. DO NOT let Mopar (TM) Parts Cleaner come in contact with eyes or skin. DO NOT ingest the cleaner. Wash thoroughly after using cleaner. a. Remove the throttle body from engine. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar (TM) Parts Cleaner. Only use Mopar (TM) Parts Cleaner to clean the throttle body. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1628 c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB Scan Tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Housing And Element REMOVAL 1. Unfasten clasps on rear of air cleaner housing cover. Lift cover off air cleaner housing. Air Cleaner Housing And Element 2. Remove filter element. 3. If necessary clean the inside of the air cleaner housing. INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps in place. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1637 Fuel Pressure Release: Service and Repair Fig. 2 Releasing Fuel Pressure Fig. 1 Fuel Pressure Test Port--Typical CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock. 1. Disconnect the fuel rail electrical harness from the engine harness. Refer to Diagrams/Electrical. 2. Connect one end of a jumper wire to the A142 circuit terminal of the fuel rail harness connector. 3. Connect the other end of the jumper wire to a 12 volt power source. 4. Connect one end of a jumper wire to a good ground source. 5. Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector. Repeat procedure for 2 to 3 injectors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Fig. 1 Spark Plug Cable Routing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Fig. 1 Spark Plug Cable Routing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 560 Ohms per Inch 3,000 Ohms per Foot 6,700 Ohms per Foot Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1648 Ignition Cable: Description and Operation Spark Plug cables are sometimes referred to as secondary ignition wires. They transfer electrical current from the distributor, to individual spark plugs at each cylinder. They transfer electrical current from the distributor to individual spark plugs at each cylinder. The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Check the spark plug cable connections for good contact at the coil and distributor cap towers and at the spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil and distributor cap towers and spark plug cover should fit tight around spark plug insulators. - Loose cable connections can cause ignition malfunctions by permitting water to enter the towers, corroding, and increasing resistance. 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. Clean high tension cables with a cloth moistened with a non-flammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1651 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from cable clips. 3. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. 4. Connect the ohmmeter between the spark plug end terminal and the corresponding electrode inside the cap. - Make sure ohmmeter probes are 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 the same manner. To test the connection between the coil and distributor terminals: 1. Remove distributor cap. 2. Connect an ohmmeter between center contact in the cap and coil tower terminal. - Resistance should be approximately 5,000 ohms. - If resistance is not within tolerance, replace the cap. - If no problems are found, refer to Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 560 Ohms per Inch 3,000 Ohms per Foot 6,700 Ohms per Foot Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, 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. WARNING: The ignition system generates approximately 32,000 volts. Personal injury could result from contact with this system. 2. With the 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. - Replace cracked, leaking or faulty cables. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 1652 Ignition Cable: Service and Repair Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 1 Spark Plug Cable Routing Remove the distributor cap and inspect the inside for: flash over - cracking of carbon button - lack of spring tension on carbon button - cracking of cap - burned, worn terminals - Also check for broken distributor cap towers. If any of these conditions are present the distributor cap and/or cables should be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection > Page 1657 Distributor Cap: Service and Repair Fig. 1 Spark Plug Cable Routing When replacing the distributor cap, transfer cables from the original cap to the new cap one at a time. Ensure each cable is installed into the corresponding tower of the new cap. Fully seat the wires into the towers. If necessary refer to the appropriate engine firing order diagram Fig. 1. Light scaling of the terminals can be cleaned with a sharp knife. If the terminals are heavily scaled, replace the distributor cap. A cap that is greasy, dirty or has a powder-like substance on the inside should be cleaned with a solution of warm water and a mild detergent. Scrub the cap with a soft brush. Thoroughly rinse the cap and dry it with a clean soft cloth. Fig. 11 Distributor Cap Screws REMOVAL & INSTALLATION 1. Remove bolt holding air inlet resonator to intake manifold. 2. Loosen clamps holding air cleaner cover to air cleaner housing. 3. Remove PCV make-up air hose from air inlet tube. 4. Loosen hose clamp at throttle body. 5. Remove air inlet tube, resonator and air cleaner cover. 6. Remove EGR tube. 7. Remove spark plug cables from distributor cap. 8. Loosen distributor cap holddown screws and remove cap Fig. 11. 9. Transfer cables from old cap to new cap. The cap is numbered and so are the cables. 10. Install distributor cap. 11. Install distributor holddown washers and nuts. Tighten nuts to 13 Nm (9 ft lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Replace the rotor if: it is cracked - the tip is excessively burned or heavily scaled - the spring terminal does not have adequate tension Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection > Page 1661 Ignition Rotor: Service and Repair Fig. 11 Distributor Cap Screws Fig. 13 Distributor Rotor Button And Spring REMOVAL 1. Remove bolt holding air inlet resonator to intake manifold. 2. Loosen clamps holding air cleaner cover to air cleaner housing. 3. Remove PCV make-up air hose from air inlet tube. 4. Loosen hose clamp at throttle body. 5. Remove air inlet tube, resonator and air cleaner cover. 6. Remove EGR tube. 7. Remove spark plug cables from distributor cap. 8. Loosen distributor cap holddown screws and remove cap Fig. 11. 9. Mark the rotor position and remove rotor. The mark indicates where to position the rotor when reinstalling the distributor. 10. Inspect rotor for cracks or burned electrode. If any of these conditions exist, replace rotor. 11. Inspect rotor button for damage. Replace button and spring as required. Pull button and spring out of cap Fig. 13. 12. Reverse the removal steps for installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .............................. 0.965-1.092 mm (0.038-0.043 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1665 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................. RC10PYP4 Thread size .................................................... ................................................................................................................................................. (14 mm) 3/4 in. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1666 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 1,000 ohm tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Remove the spark plugs and examine them for burned electrodes and 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 recommended intervals. Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. This engine uses platinum spark plugs. CAUTION: Do not attempt to adjust the gap of a platinum plug. Cleaning of the platinum plug may damage the platinum tip. If carbon deposits must be removed, use a plug cleaner and complete cleaning within 20 seconds to protect electrode. Do not use a wire brush. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1669 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1670 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1671 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1672 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. 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 COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1673 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. 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 .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1674 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1675 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection NOTE: 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. - 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 -- SEE Spark Plug Condition. 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 0.038 - 0.043 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1676 Spark Plug Overheating Overheating is indicated by a 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. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1677 Spark Plug: Adjustments Fig 2 Platinum Pads Setting Spark Plug Electrode Gap CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge Fig. 3. - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. - Gap 0.038 to 0.043 in Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1678 Spark Plug: Service and Repair Fig. 3 Intake Manifold Sensors And Left Plenum Support SPARK PLUG SERVICE When replacing the spark plug and coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Do not attempt to adjust the gap of a platinum plug. Cleaning of the platinum plug may damage the platinum tip. If carbon deposits must be removed, use a plug cleaner and complete cleaning within 20 seconds to protect electrode. Do not use a wire brush. SPARK PLUG REMOVAL Remove the spark plugs and examine them for burned electrodes and 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. SPARK PLUG REMOVAL - #2, #4 OR #6 Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1/2 turn and pulling straight back in a steady motion. 1. Prior to removing the spark plug spray compressed air around the spark plug hole and the area around the spark plug. 2. Remove the spark plug using a quality socket with a rubber or foam insert. 3. Inspect the spark plug condition. SPARK PLUG REMOVAL - #1, #3 OR #5 1. Disconnect negative cable from auxiliary jumper terminal. 2. Unplug connectors from MAP and intake air temperature sensors Fig. 3. 3. Remove plenum support bracket bolt located rearward of MAP sensor Fig. 3. 4. Remove bolt holding air inlet resonator to intake plenum Fig. 4. Fig. 4 Air Inlet Resonator 5. Loosen throttle body air inlet hose clamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1679 6. Release snaps holding air cleaner housing cover to housing. 7. Remove air cleaner cover and inlet hoses from engine. 8. Unplug TPS and idle air control motor connectors Figs. 5 and 6. 9. Pry retainer tab back on throttle cable and slide cable out of bracket Fig. 7. Remove cable from throttle lever. 10. Slide Speed control cable out of bracket, if equipped Fig. 7. Remove cable from throttle lever. 11. Remove EGR tube from intake plenum Fig. 8. Fig. 5 Throttle Sensor Position Sensor Fig. 6 Idle Air Control Module Fig. 7 Throttle Cable Attachment 12. Remove plenum support bracket bolt located rearward of EGR tube Fig. 8. 13. Remove bolts holding upper intake plenum and remove plenum. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1680 Fig. 8 EGR Tube And Right Manifold Support Bolt 14. Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1/2 turn and pulling straight back in a steady motion. 15. Prior to removing the spark plug spray compressed air around the spark plug hole and the area around the spark plug. 16. Remove the spark plug using a quality socket with a rubber or foam insert. 17. Inspect the spark plug condition. Fig 2 Platinum Pads SPARK PLUG INSTALLATION CAUTIONS: - Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. - Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. - Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicles original spark plugs that have been determined good. Do not apply anti-seize compound to new spark plugs. - Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the anti- seize compound doesn't make contact with the spark plug electrodes or ceramic insulator. - Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without following the correct procedures. - Always tighten spark plugs to the specified torque Over tightening can cause distortion resulting in a change in the spark plug gap. Over tightening can also damage the cylinder head. Tighten spark plugs to 28 Nm (20 ft. lbs.) torque. - Due to the engine packaging environment for these engines. extreme care should be used when installing the spark plugs to avoid cross threading problems. 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install ignition cables over spark plugs. 4. Install new gasket and position upper intake plenum. Tighten plenum bolts to 18 Nm (13 ft lb) torque. 5. Install bolts at plenum support brackets. Tighten bolts to 18 Nm (13 ft lb). 6. Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 in lb). 7. Install throttle and speed control (if equipped) cables. 8. Attach electrical connectors to sensors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1681 9. Tighten air inlet tube clamps to 2-4 Nm (20-30 in lb) torque. 10. Connect negative terminal to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION PRESSURE (at 250 - 400 RPM): Standard .............................................................................................................................................. ................................................. 1275 kPa (185 psi) Minimum ............................................................. ................................................................................................................................... 959 kPa (139 psi) COMPRESSION PRESSURE DIFFERENCE OF ALL CYLINDER: Maximum ............................................................................................................................................. ...................................................... 98 kPa (14 psi) VACUUM: Manifold ............................................................................................................................................... .......................................... 60 kPa (18 inches Hg) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1685 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt 17 ft.lb Water Pump Inlet Tube to Block Bolts 105 in.lb Water Pump Inlet Pipe to Cylinder Head Fasteners 123 in.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1692 Water Pump: Description and Operation GENERAL INFORMATION The water pump body is made of aluminum with a steel impeller. The water pump is bolted to the front of the block, and driven by the timing belt. The water pump is the heart of the cooling system, pumping the coolant through the engine block, cylinder head, heater core, and radiator. NOTE: The water pump on all models can be replaced without discharging the air conditioning system. MOUNTING The pump bolts directly to the engine block, using a gasket for pump to block sealing. The pump is serviced as a unit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1693 Water Pump: Testing and Inspection OPERATIONAL TEST A quick flow test to tell whether or not the pump is working is to see if the heater warms properly. A defective pump will not be able to circulate heated coolant through the long heater hose. Another flow test to help determine pump operation, remove radiator cap. CAUTION: DO NOT remove radiator cap if the cooling system is hot or under pressure. REPLACEMENT REASONS Replace the water pump if it has any of the following defects: ^ Damage or cracks on the pump body. ^ Coolant leaks, if the shaft seal is leaking, evident by traces of coolant leaks from vent hole A. ^ Impeller rubs inside of pump. ^ Excessively loose or rough turning bearing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1694 Water Pump: Service and Repair REMOVAL 1. Drain cooling system. 2. Remove the timing belt. 3. Remove mounting bolts. 4. Separate pump from water inlet pipe and remove pump. INSTALLATION 1. Clean all gasket and O-ring surfaces on pump and water pipe inlet tube. 2. Install new O-ring on water inlet pipe. Wet the O-ring with water to facilitate assembly. CAUTION: Keep the O-ring free of oil or grease. 3. Install new gasket on water pump and install pump inlet opening over water pipe, press assembly to cause water pipe insertion into pump housing. 4. Install pump to block mounting bolts and tighten to 27 Nm (20 ft. lbs). 5. Install timing belt. Reassemble engine. 6. Fill cooling system. 7. Install accessory drive belts. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1700 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ........................................................ 10.0 L (10.5 qts) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1703 Coolant: Fluid Type Specifications GENERAL INFORMATION Performance is measurable. For heat transfer pure water absorbs 1 btu for each degree of temperature rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: ^ Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). ^ 100 Percent ethylene glycol (0.7 btu) can cause an engine to run hot, cause detonation, and will freeze at -22°C (-8°F). ^ 50/50 Ethylene Glycol and Distilled Water (0.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, coolant sensor and heater are all designed for 50/50 ethylene glycol. ^ Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -46°C ( -50°F ). NOTE: Richer mixtures cannot be measured with field equipment and can lead to problems associated with 100 percent glycol. If there is doubt that the coolant mixture is to rich for field equipment to measure, put a sample in a clean container. Add exactly the same amount of water and retest. If the coolant in the vehicle is 100% antifreeze, the diluted sample will read 50%. If the coolant in the vehicle was 70% antifreeze and 30% water, the diluted sample will read as 35%, etc. SELECTION AND ADDITIVES The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or their equivalent are recommended for best engine cooling without corrosion. When mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it looses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspected water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information GENERAL INFORMATION The cooling system is designed around the coolant. PICKING UP HEAT The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. GIVING OFF HEAT Then carry this heat to the radiator where the tube/fin assemblies of these components can give off the heat to the air. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information > Page 1706 Coolant: Description and Operation Coolant Performance GENERAL INFORMATION Performance is measurable. For heat transfer pure water absorbs 1 btu for each degree of temperature rise for each pound of water. This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: ^ Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F). ^ 100 Percent ethylene glycol (0.7 btu) can cause an engine to run hot, cause detonation, and will freeze at -22°C (-8°F). ^ 50/50 Ethylene Glycol and Distilled Water (0.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, coolant sensor and heater are all designed for 50/50 ethylene glycol. ^ Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -46°C ( -50°F ). NOTE: Richer mixtures cannot be measured with field equipment and can lead to problems associated with 100 percent glycol. If there is doubt that the coolant mixture is to rich for field equipment to measure, put a sample in a clean container. Add exactly the same amount of water and retest. If the coolant in the vehicle is 100% antifreeze, the diluted sample will read 50%. If the coolant in the vehicle was 70% antifreeze and 30% water, the diluted sample will read as 35%, etc. SELECTION AND ADDITIVES The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar Antifreeze or their equivalent are recommended for best engine cooling without corrosion. When mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it looses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspected water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1707 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation CIRCUIT OPERATION The engine coolant temperature lamp is used to alert the operator that the coolant temperature has risen above the normal operating range. When the Powertrain Control Module (PCM) determines a problem, a message is sent across the CCD Bus to the Body Control Module (BCM). The PCM receives coolant temperature information from the engine coolant temperature sensor. This sensor uses a variable resistor to send a signal to the PCM indicating engine coolant temperature. The BCM processes this message and sends a signal on the CCD Bus to the instrument cluster for lamp illumination. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Short Retaining Screws ....................................................................................................................... .................................................... 3 Nm (25 inch lbs.) Tall Retaining Screws ...................................... ....................................................................................................................................... 7 Nm (65 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Information Radiator Cooling Fan Motor: Description and Operation Circuit Information CIRCUIT OPERATION The radiator fan system uses two relays located in the Power Distribution Center (PDC). One relay is used for LOW speed fan operation and the other is for HIGH speed operation. The Powertrain Control Module (PCM) controls the operation of the relays depending on engine coolant temperature or A/C operation. Power for the coil side of both relays is provided on circuit F18. This circuit is protected by a 10 amp fuse located in cavity 9 of the Power Distribution Center (PDC). Power for the contact side of the relays is provided on circuit A16. This circuit is protected by a 40 amp fuse located in cavity 19 of the PDC. When LOW speed fan operation is required the PCM grounds circuit C24. This causes the contacts in the relay to CLOSE connecting circuits A16 and C23. Circuit C23 connects from the relay to the low speed fan motor. Ground for the motor is provided on circuit Z1, which terminates at the left strut tower. When HIGH speed fan operation is required the PCM grounds circuit C27. This causes the contacts in the relay to CLOSE connecting circuits A16 and C25. Circuit C25 connects from the relay to the high speed fan motor. Ground for the motor is provided on circuit Z1, which terminates at the left strut tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Information > Page 1717 Radiator Cooling Fan Motor: Description and Operation General Information TYPE All models use electric motor driven cooling system fans. The fan modules include a motor support and shroud. The module is fastened to the radiator by bolts. OPERATION All fan motors are two speed. Attempts to reduce high temperature gauge reading by increasing engine speed, at the same vehicle speed, can increase high temperature. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Page 1718 Radiator Cooling Fan Motor: Testing and Inspection CONTROL Fan control is accomplished three ways. Turned On With A/C The fan runs when the air conditioning pressure reaches a set psi. Coolant Temperature In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the Engine Controller. The Engine Controller turns on the fan through the fan relay. Transmission Fluid Temperature On models equipped with automatic transmission, a transmission fluid thermistor may have some influences on fan operation. POWER TRAIN CONTROL MODULE INPUT The Power Train Control Module (PCM) provides fan control for the following conditions: ^ The fan will not run during cranking until the engine starts no matter what the coolant temperature is. ^ Fan will run when the air conditioning clutch is engaged, low pressure cutout switch is closed and once set compressor head pressure is reached. ^ Fan will run according to the chart in above image. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Page 1719 Radiator Cooling Fan Motor: Service and Repair REMOVAL 1. Remove the motor fasteners from support. Remove motor from support. 2. Reverse the above procedure for Installation. Tighten the short fan motor fasteners to 3 Nm (25 inch lbs.) and tighten the tall fan motor fasteners to 5 Nm (45 inch lbs.). INSTALLATION 1. Install assembly to radiator. Torque shroud to radiator fasteners to 7.5 Nm (65 inch lbs.). 2. Connect fan motor lead. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1723 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1724 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1725 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1726 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair NOTE: There are no repairs to be made to the fan. If the fan is warped, cracked, or otherwise damaged, it must be replaced with only the recommended part for adequate strength, performance and safety. REMOVAL To remove fan from motor shaft, bench support the motor and motor shaft, while removing the fan retaining clip, so that the shaft and motor will not be damaged by excessive force. Do not permit the fan blades to touch the bench. NOTE: Surface burr removal may be required to remove fan from motor shaft. INSTALLATION To install fan on motor shaft, slide the fan over shaft. Support motor and shaft as above while installing fan retaining clip. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant temperature sensor torque ..................................................................................................... .......................................................... 27 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1734 Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor And Oil Pressure Switch Locations Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1735 Engine Coolant Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1736 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor is installed in the housing between the filler neck and thermostat Fig. 7. The sensor provides an input voltage to the PCM. The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emissions and improve driveability - Because spark advance changes at different engine operating temperatures during warm-up, all spark advance testing should be done with the engine fully warmed. The PCM demands slightly richer air-fuel mixtures and higher idle speeds until the engine reaches normal operating temperature. The engine coolant sensor input is also used for radiator fan control. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. This sensor input is also used for the instrument cluster coolant temperature gauge. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 4 Engine Coolant Temperature Sensor 1. With key off, disconnect wire connector from engine coolant temperature sensor Fig. 4. 2. Connect one lead of ohmmeter to one terminal of engine coolant temperature sensor. 3. Connect the other lead of ohmmeter to remaining terminal of engine coolant temperature sensor. The ohmmeter should read as follows; - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F, ohmmeter should read approximately 7,000 to 13,000 ohms. 4. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between connector terminal 43 and the sensor harness connector. Refer to Wiring Diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 1739 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 1740 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. REMOVAL 1. Drain cooling system until coolant level is below engine coolant temperature sensor. Refer to Cooling System. 2. Disconnect electrical connector from sensor. 3. Remove sensor from engine. INSTALLATION 1. Install ECT sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Description and Operation Fan Shroud: Description and Operation All vehicles have fan shrouds to improve fan air flow efficiency. The shroud supports the electric fan motor and fan. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core is located in the heater-A/C housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the amount of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged. it must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 1747 Heater Core: Service and Repair Fig 29 Control Module NOTE: The heater core is serviceable inside the vehicle. However, if the core has leaked a significant amount of coolant, the A/C housing must be removed. The housing should be disassembled and cleaned thoroughly before heater core replacement. If housing removal is necessary, refer to Service and Repair. REMOVAL 1. Disconnect battery negative remote cable. 2. Remove radio/control module bezel. 3. Remove right instrument panel side trim. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 4. Remove two screws at lower right side support beam. 5. Remove bolt for instrument panel support at A-pillar. 6. Remove left instrument panel side trim. 7. Remove upper instrument panel bezel. 8. Remove lower knee bolster. 9. Remove console screws at instrument panel. 10. Remove gearshift knob. 11. Remove shifter bezel. 12. Remove console screws at rear. Remove rear half of console. 13. Remove front console screws. Remove front half of console. 14. Remove right side instrument panel support strut. 15. Drain coolant. Refer to: "Engine, Cooling and Exhaust : Service and Repair" See: Service and Repair 16. Remove heater hoses at cowl. 17. Remove heater core cover screws and cover. 18. Remove heater core. INSTALLATION 1. Carefully install new heater core into the heater housing. 2. Fasten heater core cover to housing with screws provided. 3. Reinstall all necessary trim. 4. Fill coolant to level. 5. Reconnect battery. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair Fig 57 Heater Hose Connection At Engine NOTE: The heater hoses used are preformed hoses with quick connect fittings at the engine. These hoses are not serviceable and must be replaced using OEM parts. The hoses are attached at the heater core using spring tension clamps. NOTE: Review Safety Precautions and Warnings before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Using thin slide-jaw pliers, pinch quick connect fitting in, of hose to be removed. 3. Remove intake manifold plenum. Fig 56 Heater Hose Connection At Heater Core 4. Using spring tension clamp pliers, remove clamp at heater core end of hose to be removed. 5. Carefully rotate hose back and forth while tugging slightly away from connector nipple. 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 into heater unit. INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation CIRCUIT OPERATION The engine coolant temperature lamp is used to alert the operator that the coolant temperature has risen above the normal operating range. When the Powertrain Control Module (PCM) determines a problem, a message is sent across the CCD Bus to the Body Control Module (BCM). The PCM receives coolant temperature information from the engine coolant temperature sensor. This sensor uses a variable resistor to send a signal to the PCM indicating engine coolant temperature. The BCM processes this message and sends a signal on the CCD Bus to the instrument cluster for lamp illumination. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The engine coolant temperature gauge receives its information across the CCD Bus from the Body Control Module (BCM). The engine coolant temperature sensor uses a variable resistor to send a signal to the Powertrain Control Module (PCM) indicating coolant temperature. The PCM then sends this information to the BCM across the CCD Bus. The BCM calculates the position of the engine coolant temperature gauge and based on the information received from the PCM it adjusts the position of the gauge pointer. This signal is sent over the CCD Bus to the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1758 Temperature Gauge: Testing and Inspection At idle the temperature gauge could rise slowly to about 1/2 gauge travel. The fan will come on and the gauge could drop to about 1/3 gauge travel, this is normal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1759 Temperature Gauge: Service and Repair REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Fuel Gauge And Temperature Gauge Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1760 4. Remove the fuel/temperature gauge attaching screws from the housing and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair CAUTION: Plastic tanks, while stronger then brass are subject to damage by impact, such as wrenches. REMOVAL Turn the drain cock stem counterclockwise to unscrew the stem. When the stem is unscrewed to the end of the threads, pull the stem from the radiator tank. NOTE: To open draincock on this vehicle, use a 3/8 inch drive extension 3" long, a 19mm socket with universal. INSTALLATION 1. Push the draincock assembly body into the tank opening until it snaps into place. 2. Tighten the draincock stem by turning clockwise to 2.0 - 2.7 Nm (18 - 25 inch lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation GENERAL INFORMATION The cooling system is equipped with a pressure cap that releases pressure at some point within a range of 97 - 124 kPa (14 - 18 psi). The system will operate at higher than atmospheric pressure, which raises the coolant boiling point, allowing increased radiator cooling capacity. VENT VALVE There is a vent valve in the center of the cap that allows a small coolant flow to the Coolant Recovery System (CRS) tank. If the valve is stuck shut, the radiator hoses will collapse on cool-down. Clean the vent valve to ensure proper sealing when boiling point is reached. GASKET There is a gasket in the cap that seals to the top of the filler neck so that vacuum is maintained to draw coolant back into the system from the coolant reserve system tank. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Cap: Initial Inspection and Diagnostic Overview RIGHT SIDE UP Hold the cap in your hand, right side up. The vent valve at the bottom of the cap should open. If the rubber gasket has swollen, preventing the valve from opening, replace the cap. UPSIDE DOWN Hold the cleaned cap in your hand, upside down. If any light can be seen between vent valve and the rubber gasket, replace the cap. Do not use a replacement cap that has a spring to hold the vent shut. NOTE: A replacement cap must be of the type designed for coolant reserve systems. This design ensures coolant return to the radiator. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1770 Radiator Cap: Component Tests and General Diagnostics Radiator Cap - Pressure Testing Dip the pressure cap in water; clean off any deposits on the vent valve or its seat, and apply the cap to end of radiator pressure tester. Working the plunger, increase the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the cap. CAUTION: The radiator pressure tester is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn the tool upside down, and recheck the pressure cap to confirm that the cap is faulty. NOTE: If the pressure cap tests properly while positioned the on radiator pressure tester, but will not hold pressure or vacuum when positioned on the filler neck, inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. Radiator Cap to Filler Neck Seal - Pressure Relief Check The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple. Attach the radiator pressure tester to the filler neck nipple, and pump air into the system. The pressure cap upper gasket should relieve pressure at 69 - 124 kPa (10 - 18 psi) , and hold pressure at 55 kPa (8 psi) minimum. WARNING: THE WARNING WORDS DO NOT OPEN HOT ON THE PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, THE COOLING SYSTEM BUILDS UP PRESSURE. TO PREVENT SCALDING OR OTHER INJURY, THE PRESSURE CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT AND/OR UNDER PRESSURE. There is no need to remove the pressure cap at any time except for the following purposes: ^ Check and adjust coolant freeze point ^ Refill system with new coolant ^ Conducting service procedures ^ Checking for leaks WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. PLACE A SHOP TOWEL OVER THE CAP, AND WITHOUT PUSHING DOWN, ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE. WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE COOLANT RECOVERY SYSTEM (CRS) TANK AND PRESSURE DROPS, PUSH DOWN ON THE CAP AND REMOVE IT COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTER-CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE. CAUTION: ^ Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing constant tension clamps. ^ A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter. HOSES Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. CLAMPS Spring type hose clamps are used in all applications. If replacement is necessary replace with the original Mopar equipment spring type clamp. The hose clamps are removed by using Special Tool 6094, or equivalent constant tension clamp pliers to compress hose clamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1778 Radiator Cooling Fan Motor Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1779 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1780 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1781 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant temperature sensor torque ..................................................................................................... .......................................................... 27 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1787 Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor And Oil Pressure Switch Locations Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1788 Engine Coolant Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1789 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor is installed in the housing between the filler neck and thermostat Fig. 7. The sensor provides an input voltage to the PCM. The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emissions and improve driveability - Because spark advance changes at different engine operating temperatures during warm-up, all spark advance testing should be done with the engine fully warmed. The PCM demands slightly richer air-fuel mixtures and higher idle speeds until the engine reaches normal operating temperature. The engine coolant sensor input is also used for radiator fan control. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. This sensor input is also used for the instrument cluster coolant temperature gauge. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 4 Engine Coolant Temperature Sensor 1. With key off, disconnect wire connector from engine coolant temperature sensor Fig. 4. 2. Connect one lead of ohmmeter to one terminal of engine coolant temperature sensor. 3. Connect the other lead of ohmmeter to remaining terminal of engine coolant temperature sensor. The ohmmeter should read as follows; - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F, ohmmeter should read approximately 7,000 to 13,000 ohms. 4. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between connector terminal 43 and the sensor harness connector. Refer to Wiring Diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Component Testing > Page 1792 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Page 1793 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. REMOVAL 1. Drain cooling system until coolant level is below engine coolant temperature sensor. Refer to Cooling System. 2. Disconnect electrical connector from sensor. 3. Remove sensor from engine. INSTALLATION 1. Install ECT sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The engine coolant temperature gauge receives its information across the CCD Bus from the Body Control Module (BCM). The engine coolant temperature sensor uses a variable resistor to send a signal to the Powertrain Control Module (PCM) indicating coolant temperature. The PCM then sends this information to the BCM across the CCD Bus. The BCM calculates the position of the engine coolant temperature gauge and based on the information received from the PCM it adjusts the position of the gauge pointer. This signal is sent over the CCD Bus to the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1797 Temperature Gauge: Testing and Inspection At idle the temperature gauge could rise slowly to about 1/2 gauge travel. The fan will come on and the gauge could drop to about 1/3 gauge travel, this is normal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1798 Temperature Gauge: Service and Repair REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Fuel Gauge And Temperature Gauge Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1799 4. Remove the fuel/temperature gauge attaching screws from the housing and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Opening Temperature ......................................................................................................................... .............................................................. 82°C (180°F) Full Open Position .......................................... .................................................................................................................................................. 95°C (203°F) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1803 Thermostat: Locations The engine thermostat is located in a thermostat housing, located below the throttle body. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1804 Thermostat: Description and Operation LOCATION The engine thermostat is located in a thermostat housing, located below the throttle body. GENERAL INFORMATION This thermostat has an air bleed valve, located in the thermostat flange. The engine cooling thermostats are wax pellet driven, reverse poppet choke type. PURPOSE They are designed to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature of 88 - 93°C (192 - 199°F). They also automatically reach wide open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat. OPERATION The thermostat is operated by a wax filled container (pellet) which is sealed so that when heated to a predetermined temperature. The wax expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1805 Thermostat: Testing and Inspection GENERAL INFORMATION The thermostat is operated by a wax filled container (Pellet) which is sealed so that when heated to a predetermined temperature. The wax expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver. IMPROPER OPERATION The thermostat that opens too soon type failure mode is included in the on-board diagnosis. The check engine light will not be lit by an open too soon condition. If it has failed open, code 17 will be set. Do not change a thermostat for lack of heater performance or temperature gage position, unless code 17 is present. Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1806 Thermostat: Service and Repair REMOVAL 1. Drain cooling system to the thermostat level or below. 2. Remove inlet hose and coolant elbow from thermostat housing. 3. Remove thermostat assembly, and clean sealing surfaces. INSTALLATION 1. Install thermostat into the recess in the thermostat housing. 2. Install inlet elbow and tighten the bolts to 12 Nm (133 inch lbs ). 3. Fill cooling system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Bolt ...................................................................................................................................................... ..................................................... 19 Nm (13 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt 17 ft.lb Water Pump Inlet Tube to Block Bolts 105 in.lb Water Pump Inlet Pipe to Cylinder Head Fasteners 123 in.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1813 Water Pump: Description and Operation GENERAL INFORMATION The water pump body is made of aluminum with a steel impeller. The water pump is bolted to the front of the block, and driven by the timing belt. The water pump is the heart of the cooling system, pumping the coolant through the engine block, cylinder head, heater core, and radiator. NOTE: The water pump on all models can be replaced without discharging the air conditioning system. MOUNTING The pump bolts directly to the engine block, using a gasket for pump to block sealing. The pump is serviced as a unit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1814 Water Pump: Testing and Inspection OPERATIONAL TEST A quick flow test to tell whether or not the pump is working is to see if the heater warms properly. A defective pump will not be able to circulate heated coolant through the long heater hose. Another flow test to help determine pump operation, remove radiator cap. CAUTION: DO NOT remove radiator cap if the cooling system is hot or under pressure. REPLACEMENT REASONS Replace the water pump if it has any of the following defects: ^ Damage or cracks on the pump body. ^ Coolant leaks, if the shaft seal is leaking, evident by traces of coolant leaks from vent hole A. ^ Impeller rubs inside of pump. ^ Excessively loose or rough turning bearing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1815 Water Pump: Service and Repair REMOVAL 1. Drain cooling system. 2. Remove the timing belt. 3. Remove mounting bolts. 4. Separate pump from water inlet pipe and remove pump. INSTALLATION 1. Clean all gasket and O-ring surfaces on pump and water pipe inlet tube. 2. Install new O-ring on water inlet pipe. Wet the O-ring with water to facilitate assembly. CAUTION: Keep the O-ring free of oil or grease. 3. Install new gasket on water pump and install pump inlet opening over water pipe, press assembly to cause water pipe insertion into pump housing. 4. Install pump to block mounting bolts and tighten to 27 Nm (20 ft. lbs). 5. Install timing belt. Reassemble engine. 6. Fill cooling system. 7. Install accessory drive belts. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Locations Fig. 1 Exhaust System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Locations > Page 1820 Catalytic Converter: Service Precautions The combustion reaction caused by the catalyst releases additional heat in the exhaust system, causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders if exhaust system is equipped with a catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning the catalyst core. Do not allow engine to operate above 1,200 RPM in neutral for extended periods over 5 minutes. This condition may result in excessive exhaust system /floor pan temperatures because of no air movement under the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter Operation Catalytic Converter: Description and Operation Catalytic Converter Operation PURPOSE The three-way catalytic converter, together with the closed loop air-fuel ratio control (based on the oxygen sensor signal) oxidizes carbon monoxides (CO) and hydrocarbons (HC), and reduces nitrogen oxides (NOx). When the mixture is controlled at stoichiometric air-fuel ratio, the three-way catalytic converter provides the highest purification against CO, HC, and NOx. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter Operation > Page 1823 Catalytic Converter: Description and Operation Catalytic Converter Efficiency Failure NAME OF CODE: Catalytic Converter Efficiency Failure WHEN MONITORED: After engine warm up to 170°F, 180 seconds of closed loop operation, open throttle, at a speed >20 mph, with the engine at 1560 - 2460 RPM and MAP at 270 - 380 mm Hg (10.5 - 15 in Hg). SET CONDITION: As the converter loses the ability to store oxygen, efficiency drops, and the concentration of oxygen becomes the same downstream as upstream. The output voltage of the downstream O2S copies that of the upstream sensor with a time lag (seen by the Powertrain Control Module (PCM)) between the switching of the O2S's. The Malfunction Indicator lamp (MIL) illuminates after 2 trips and remains ON, but goes out if the conditions that set the trouble code are not found on subsequent trips. THEORY OF OPERATION: The catalyst monitor uses oxygen sensors (O2S's) to monitor the efficiency of the converter. The dual O2S strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter. As the converter absorbs the oxygen, there is a lack of oxygen downstream of the converter and the output of the downstream O2S indicates limited activity. The downstream O2S detects oxygen content in treated gases that passed the converter. The PCM monitors lean-to-rich switches of the dual O2S's. A ratio of downstream to upstream switches closer to 0 indicates an operational catalyst, while a 1:1 ratio indicates an ineffective catalyst. PROBABLE CAUSES: - Catalytic converter - Exhaust leaks upstream of catalyst - Contaminated fuel - Mechanical engine problem Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1824 Catalytic Converter: Testing and Inspection INSPECTION Inspect for damage, cracking or deterioration. Replace the catalytic converter if obvious damage is found. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Removal Catalytic Converter: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed. 2. Remove clamp and supports at muffler to resonator assembly. Remove muffler from resonator pipe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Removal > Page 1827 3. Remove ground strap. 4. Remove clamp and supports at the resonator pipe to catalytic converter slip joint. Separate at slip joint and remove the resonator assembly. 5. Disconnect downstream heated oxygen sensor from the catalytic converter pipe. 6. Disconnect upstream heated oxygen sensor. 7. Remove catalytic converter to exhaust manifold attaching fasteners. Remove catalytic converter from vehicle. 8. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used; ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Removal > Page 1828 Catalytic Converter: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and supports have equal load on them. 1. Assemble catalytic convertor to exhaust manifold connection. 2. Assemble resonator pipe to catalytic convertor and attach to the supports on the underbody. 3. Install the muffler to resonator pipe and attach to the supports on the underbody. 4. Working from the front of system; 5. Align and tighten the catalytic convertor to exhaust manifold fasteners to a torque of 32 Nm (24 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Removal > Page 1829 6. Align each component to maintain position and proper clearance with underbody parts and that all supports have equal load on them. Tighten clamps to 80 Nm (60 ft. lbs.). 7. Connect ground strap. 8. Connect the downstream heated oxygen sensor. 9. Connect the upstream heated oxygen sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications Exhaust Crossover Pipe: Specifications Fasteners ............................................................................................................................................. ................................................. 31 Nm (275 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Flatness Standard 0.006 in Service Limit 0.012 in Torque Specifications Exhaust Manifold Nut 33 ft.lb Exhaust Manifold Flange Fasteners 24 ft.lb EGR Tube to Exhaust Manifold 97 in.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1836 Exhaust Manifold: Description and Operation The exhaust manifolds are made of ductile cast iron with the front bank and rear bank independent of each other. The exhaust from the front bank exhaust manifold is fed through a exhaust crossover pipe to be combined with the rear bank exhaust at the exhaust outlet to the exhaust pipe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation REMOVAL 1. Raise vehicle and disconnect exhaust pipe from rear (cowl side) exhaust manifold at Flex joint. It may be necessary to remove the entire exhaust system. 2. Remove bolts attaching cross-under pipe to manifolds. Remove assembly. 3. Remove heat shield from rear exhaust manifold. 4. Remove Power Steering pump bracket. 5. Remove nuts attaching rear manifold to cylinder head and remove manifold. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1839 6. Lower vehicle and remove screws attaching front heat shield to front manifold. NOTE: Install a new exhaust manifold gasket. INSTALLATION 1. Install the rear exhaust manifold and tighten attaching nuts to 30 Nm (22 ft. lbs.). 2. Install rear exhaust manifold heat shield torque fastener to 13 Nm (115 inch lbs.). 3. Install Power Steering Pump bracket to engine. 4. Attach the flex-joint exhaust manifold and tighten fasteners to 28 Nm (250 inch lbs.). 5. Connect rear heated oxygen sensor lead. 6. Attach cross-under pipe to exhaust manifold and tighten bolt to 31 Nm (275 inch lbs.). 7. Install front exhaust manifold and attach exhaust cross-under pipe tighten fastener to 31 Nm (275 inch lbs.). 8. Install front manifold heat shield and tighten attaching screws to 15 Nm (130 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1840 Exhaust Manifold: Service and Repair Cleaning and 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Removal Exhaust Pipe: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed. 2. Remove clamp and supports at muffler to resonator assembly. Remove muffler from resonator pipe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Removal > Page 1845 3. Remove ground strap. 4. Remove clamp and supports at the resonator pipe to catalytic converter slip joint. Separate at slip joint and remove the resonator assembly. 5. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used; ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Removal > Page 1846 Exhaust Pipe: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and supports have equal load on them. 1. Assemble resonator pipe to catalytic convertor and attach to the supports on the underbody. 2. Install the muffler to resonator pipe and attach to the supports on the underbody. 3. Working from the front of system; 4. Align each component to maintain position and proper clearance with underbody parts and that all supports have equal load on them. Tighten clamps to 80 Nm (60 ft. lbs.). 5. Connect ground strap. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Fastener .............................................................................................................................................. ...................................................... 80 Nm (60 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal Exhaust Pipe/Muffler Hanger: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed. 2. Remove clamp and supports at muffler to resonator assembly. Remove muffler from resonator pipe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal > Page 1852 3. Remove ground strap. 4. Remove clamp and supports at the resonator pipe to catalytic converter slip joint. Separate at slip joint and remove the resonator assembly. 5. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used; ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal > Page 1853 Exhaust Pipe/Muffler Hanger: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and supports have equal load on them. 1. Assemble resonator pipe to catalytic convertor and attach to the supports on the underbody. 2. Install the muffler to resonator pipe and attach to the supports on the underbody. 3. Working from the front of system; 4. Align each component to maintain position and proper clearance with underbody parts and that all supports have equal load on them. Tighten clamps to 80 Nm (60 ft. lbs.). 5. Connect ground strap. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Manifold Heat Shield ........................................................................................................................... ............................................... 13 Nm (115 inch lbs.) Body Shields .................................................... ....................................................................................................................................... 5 Nm (40 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1857 Heat Shield: Description and Operation PURPOSE Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed near the catalytic converters. All engines are equipped with a heat shield crimped on the top of the convertor. NOTE: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped. Light over spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. CAUSES OF HEAT The combustion reaction caused by the catalyst releases additional heat in the exhaust system. Causing temperature increases in the area of the catalytic convertor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders if exhaust system is equipped with catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. NOTE: The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan temperatures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed. 2. Remove clamp and supports at muffler to resonator assembly. Remove muffler from resonator pipe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 1862 3. Remove ground strap. 4. Remove clamp and supports at the resonator pipe to catalytic converter slip joint. Separate at slip joint and remove the resonator assembly. 5. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used; ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 1863 Muffler: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and supports have equal load on them. 1. Assemble resonator pipe to catalytic convertor and attach to the supports on the underbody. 2. Install the muffler to resonator pipe and attach to the supports on the underbody. 3. Working from the front of system; 4. Align each component to maintain position and proper clearance with underbody parts and that all supports have equal load on them. Tighten clamps to 80 Nm (60 ft. lbs.). 5. Connect ground strap. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Service and Repair > Removal Exhaust Resonator: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed. 2. Remove clamp and supports at muffler to resonator assembly. Remove muffler from resonator pipe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Service and Repair > Removal > Page 1868 3. Remove ground strap. 4. Remove clamp and supports at the resonator pipe to catalytic converter slip joint. Separate at slip joint and remove the resonator assembly. 5. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used; ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Service and Repair > Removal > Page 1869 Exhaust Resonator: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and supports have equal load on them. 1. Assemble resonator pipe to catalytic convertor and attach to the supports on the underbody. 2. Install the muffler to resonator pipe and attach to the supports on the underbody. 3. Working from the front of system; 4. Align each component to maintain position and proper clearance with underbody parts and that all supports have equal load on them. Tighten clamps to 80 Nm (60 ft. lbs.). 5. Connect ground strap. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations ETACS-ECU ETACS-ECU Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1879 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1880 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1881 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1882 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1883 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1884 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1885 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1886 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1887 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1888 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1889 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1890 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1891 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1892 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1893 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1894 Body Control Module: Connector Views Body 20 Way Connector (At BCM) Engine 14 Way Connector (At BCM) Instrument Panel 10-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1895 Instrument Panel 22-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1896 Body Control Module: Electrical Diagrams Body Control Module Wiring Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1897 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1898 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1899 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1900 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1905 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1906 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information Technician Safety Information WARNING: Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. 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. SERVICING SUB-ASSEMBLIES 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. Only those components with approved Service and Repair procedures in this database should be serviced. DRBIII Scantool Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRB if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. - Do not exceed the limits shown in the table above. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 1909 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". 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 because of corrosion. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms Body Control Module: Application and ID Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The terms "gage" and "gauge" are used interchangeably Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms > Page 1912 Body Control Module: Application and ID Body Codes Defined JA ............................................................................................................................................................ Chrysler Cirrus, Plymouth Breeze, Dodge Stratus JX ......................................................................... ................................................................................................................... Chrysler Sebring Convertible Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Active Codes: A malfunction that is present now. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1915 ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1916 Body Control Module: Description and Operation Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1917 Body Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1918 Body Control Module: Description and Operation Climate Control Systems A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1919 Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1920 Active Codes: A malfunction that is present now. ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1921 protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Compass Mini-Trip Computer (CMTC) COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located on the right hand side of the instrument cluster. The CMTC is an electronic control module with a Vacuum Fluorescent Display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. Upon ignition the CMTC will turn on all of the segments in the display for 1 second then reverts to the last function screen that was displayed prior to the last ignition cycle. The functions that are available via actuation of the STEP switch are as follows: - Compass and Ambient Temperature - Average Trip Fuel Economy (AVE ECO) - Estimated Range (RANGE) - Present Fuel Economy (ECO) - Trip Odometer (ODO) - Elapsed Ignition On Time (ET) - Blank Screen (off) Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1922 NOTE: The terms "gage" and "gauge" are used interchangeably Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of four gauges, the status of seven indicator lamps, the status and dimming of the PRNDL indicator (VF display), and the dimming of cruise and low fuel lamps to the Mechanical Instrument Cluster (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run," or "start" positions. The PRNDL indicator works when the ignition is in the "off," "run," or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all PRNDL segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the tachometer exceeds 450 rpm. Power Door Lock System POWER DOOR LOCK SYSTEM When the Body Control Module (BCM) receives an input for a lock/unlock request (door lock switch, Remote Keyless Entry (RKE), or door key cylinder switch (w/VTSS only), it will ground the appropriate relay for a specified amount of time. For this vehicle all door lock relays are located inside the body control module and are not serviced separately. The door lock switches provide a variable voltage (Multiplexed (MUX) circuit) to the BCM and the BCM will respond to that command. If the conditions for door lock inhibit exist (key in ignition and left front door open), the BCM will not respond to a lock command. Other power door lock features: Automatic Door Locks This feature can be enabled/disabled by using either the DRB, MDS machine or customer key cycle method. When enabled, all the doors will lock when the vehicle reaches a speed greater than 15 MPH, all doors are closed and an increase of TPS signal is received by the PCM. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the vehicle speed accelerates above 15 MPH. Remote Keyless Entry (RKE) The body control module receives and decodes messages from the remote keyless entry transmitter. The remote keyless entry module is built into the BCM (premium) and is not serviced separately. When the lock button is pressed all doors will lock, horn will chirp, courtesy lamps will turn off and VTSS (if equipped) will arm. When the unlock button is pressed once, the left front door will unlock, courtesy lamps will light (if equipped w/illuminated entry) and VTSS (if equipped) will disarm. If the unlock button is pressed a second time (within 5 seconds of the first), all the other doors will unlock. Panic mode (if equipped with VTSS), is accomplished by pressing both lock and unlock buttons at the same time. 1997 JX transmitters have a separate panic button. This flashes the lights and sounds the horn but does not prevent the engine from running. The BCM will ignore all commands from the transmitter if the vehicle speed is over 15 MPH. This allows the engine to be running during warm up on cold days and then using the RKE to unlock the doors. The RKE software can store up to 4 transmitter codes. Rolling Code (97 JX only) The rolling code features changes part of the key fob (transmitter) message each time it is used. The key fob message and the receiver message increment together. Under certain conditions with a rolling code system (like pressing a button on the fob over 250 times outside of the receiver range) the receiver and transmitter can fall out of synchronization. By pressing specific buttons together, the system will re-synchronize. Radio-CCD RADIO - CCD NOTE: At the present time all 1997 CCD radios are not connected to the CCD bus. The audio systems used in the JX convertible will consist of one of the following radios: RAL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1923 RAL - Base radio with AM/FM stereo, bass and treble sliders only. RBS RBS - AM/FM stereo with cassette tape and CD changer option. Bass and treble controls. This radio may or may not be addressable with DRB. If it is equipped with the Premium Amplifier option (located under the passenger seat), it will be on the CCD bus. The Amplifier will determine whether the CCD connector in the back of the radio is wired. RBR RBR - AM/FM stereo with CD player only. Three band E.Q. Not connected to the bus. Not addressable with DRB. RAZ RAZ - AM/FM stereo with cassette and CD player incorporated into one unit. This system will be equipped with the Premium Amplifier package and will be addressable with the DRB. The amplifier as above is located under the passenger seat. The audio systems available in the JX are made up of the four corporate radios listed above with some additional options with regard to the amplification system. The list breaks down how the separate systems are made up. There are only two of the four radios that will be addressable on the CCD bus with the DRB. The key to knowing which system is addressable is the presence of an amplifier under the passenger seat. This amplifier utilizes a different instrument panel wiring harness that incorporates the CCD connector for the radio. Some of the radios may have a CCD connector in the radio chassis that may not have a connector plugged into it. This is entirely normal if there is no amplifier under the passenger seat. The RBS radio will be available with or without the premium amplifier and therefore will not be addressable via the CCD bus in some packages. When equipped with a Premium Amplifier package, there will be six speakers in the can The amplifier will drive the instrument panel speakers and the door speakers, while the radio will drive the speakers located in the rear quarter panels directly. This means that a "shorted channel" DTC can now be caused by a problem with the wiring or the resistance of the rear quarter panel speakers. In the past, the amplifier (if equipped) drove all the speakers and consequently the circuits from the amplifier to the speakers and the speakers themselves could not be the cause of a shorted channel DTC. 3.8.1 Diagnostics DIAGNOSTICS The RBS radio has several diagnostic messages that may be displayed in the event of a problem with either the radio or the CD changer option. These messages will be displayed on the radio faceplate in the following abbreviated form. The messages are as follows: Display Definition E L-SP LEFT CHANNEL SHORT Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1924 E R-SP RIGHT CHANNEL SHORT E EJCT CANNOT EJECT TAPE E LOAD CANNOT LOAD TAPE E PLAY CANNOT PLAY TAPE The following messages are for the CD changer options; E HOT THE CD CHANGER INTERNAL TEMPERATURE IS TOO HIGH E E-O1 CD CHANGER DEADLOCK (CD JAMMED, CAN'T LOAD OR EJECT) E E-06 CD CHANGER ELEVATOR ERROR E E-07 MAGAZINE EJECT ERROR E EEEE COMMUNICATIONS ERROR (BETWEEN RADIO AND CHANGER) E PLAY CANNOT READ ALL DISCS The left channel short, right channel short and communication error between the radio and CD changer are addressed in the diagnostics. Generally, the rest of the messages will require removal and repair of either the radio or the CD changer. NOTE: When using the diagnostic manual for troubleshooting radio systems, all voltages are D.C. unless otherwise specified. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The Vehicle Theft Security System (VTSS) module is a logic-controlled device (part of the body control module), that monitors vehicle doors, trunk key cylinder, and ignition action for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, courtesy and VTSS lamps, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the cluster will flash fast for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the trunk key cylinder switch is not seen by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. The indicator lamp blinks at a slow rate when the system is armed. For 1997 JX vehicles, once the VTSS is armed the universal garage door opener (if equipped) and the decklid release switch in the center console will be disabled. The decklid release will still operate from the RKE or using the key. When something triggers the alarm, the system will signal for about 18 minutes. For the first three minutes the horn will sound, then the headlamps and courtesy lamps will continue to flash for another 15 minutes. Tamper Alert - If the horn sounds three times when either front door is unlocked, it means the alarm was activated. Check the vehicle for tampering. The VTSS indicator lamp will also flash twice quickly to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by communication between the powertrain control module and the body control module. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1925 System Self-Tests - NOTE: System self-tests can be entered only with the DRB or MDS machine. Upon entering diagnostics, the headlamps, courtesy lamps and VTSS lamp will begin flashing to verify their operation. In addition, the horn will sound twice. Removing the key from the ignition switch will stop the lamps from flashing while keeping the system in diagnostics. While in diagnostics mode, a horn pulse should occur at each of the following events, which indicates proper operation. 1. Beginning with all doors closed, open, then close each door. The horn will sound when the door ajar switch closes, and then again when the switch opens. There must be a one-second delay between closing and opening the switch. 2. Rotate the key in each door lock cylinder to the unlock position. The horn will sound as the switch closes, and again when it opens. There must be a one-second delay between changing switch states, or the horn will not sound. 3. Cycle the key to the ignition RUN position. A single horn pulse will indicate proper operation of the ignition input. This also will take the module out of the diagnostics mode. For any of these tests, if the switch does not remain open or closed for at least one second, the horn will only sound once. The lack of a horn pulse during any operation indicates either: - a switch failure - the lack of that input to the vehicle theft security system module - a failure internal to the module - a faulty horn system Check for continuity at the switch. If this is good, check for an open or shorted wire between the switch and alarm module. Also, check if the Powertrain Control Module (PCM) has been replaced recently. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Vehicle Communication VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate 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 the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver 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 code determines the message that has higher priority, which is then allowed to access the bus first. The two wires 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. 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: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection for diagnostic and repair procedures. Any of the following bus failure messages may be displayed: Short to Battery Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground Either or both of the bus wires are shorted to ground or a specific ground may be open. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 1926 Bus (+) & (-) Shorted Together The two bus wires are shorted together. No Termination The bus system has lost connection with all of its terminators. Bus Bias Level Too Low Either or both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High Either or both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias The bus system has lost connection with all modules that provide bias. Bus (+) Open The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open The bus (-) wire has lost connection with termination and/or bias. Not Receiving Bus Messages Correctly The DRB cannot communicate over the bus and does not know why. Wiper System WIPER SYSTEM The front wiper system provides the driver with normal wipe (low and high speeds), intermittent wipe, wiper after wash, and mist wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. Other wiper system features: Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled providing a range of from 1 second to 36 seconds. Mist Wipe When the wiper is in the off position and the driver presses the mist control for more than 125 msec, 1 wipe cycle in low speed mode will be provided. The wipe will continue in low speed as long as the switch is held in that position. Wiper After Wash Mode When the driver presses the wash button for over 3/8 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Body Control Module: Reading and Clearing Diagnostic Trouble Codes Displaying & Reading Trouble Codes CCD Data Link Connector Tip: Reading codes requires the use of a DRBII Diagnostic Readout Box or Equivalent Scan Tool. WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 10 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. NOTE: These diagnostic test procedures have been designed specifically for use with the Chrysler DRBII (Diagnostic Readout Box II). However it should be possible to perform the same tests using an equivalent Scan Tool. NOTE: It is not necessary to perform all of the tests in Diagnostic Charts to diagnose an individual code. Clearing Trouble Codes To clear codes, all codes must be "read," then proceed as follows: 1. After all codes have been read, press ATM. The display will change to the ERASE menu screen. 2. Press "1 ERASE CODES" to erase all codes. The display will return to the airbag menu screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 1929 Body Control Module: Component Tests and General Diagnostics Diagnostic Notes - Read First 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. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active code(s). Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. 3.12.1 Active Codes ACTIVE CODES An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. 3.12.2 Stored Codes STORED CODES Airbag codes are automatically stored in the ACM's memory when the ignition is turned off with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 1930 If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on," wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Manual A/C (HVAC) - Mode Door Operation MANUAL A/C (HVAC) MODE DOOR OPERATION The DRB trouble codes that indicate a stall failure or a feedback signal failure work together to show what is wrong with the HVAC system. The stall trouble codes mean that the Body Control Module (BCM) cannot force an actuator to the end of the mode door travel. Internal problems in the body control module will set other short-related trouble codes. Having only stall trouble codes indicates that there is a problem with an open or short circuit in the wiring, a bad actuator, a bad mode door or connecting linkage. It is important that the operation of the mode door be checked if an actuator is removed. This can be checked by rotating the door shaft to confirm that the door will stop at both ends of travel. The actuator itself has no stops. It must have the mode door to stop travel to pass the stall test. A feedback signal failure can occur on the mode door. The body control module monitors the feedback signal to check the position of the actuator. The body control module not only checks the level of the signal but also how much the voltage changes. A feedback failure can occur if there is a short or open circuit in the wiring, a bad actuator, a bad body control module, a bad mode door or connecting linkage. The easiest way to diagnose this is to use the DRB to actuate the mode door. Note that the feedback voltage of the actuator should smoothly change as the actuator is moved. A sudden change in the feedback voltage to a 5.0-volt or a 0.0-volt level indicates the actuator is bad. A fixed feedback voltage that is less than 5.0 volts or greater than 0.0 volts without a stall failure, or a short failure indicates that the actuator, the mode door, or a connecting mechanical linkage is jammed preventing movement. A feedback signal voltage that stays on 5.0 volts or 0.0 volts indicates a wiring or body control module problem. The feedback failure trouble code can also occur from a lack of actuator travel. This can be checked by confirming that the feedback signal smoothly changes when the actuator is moved with the DRB. If the signal is ok, the door travel is not correct. The actuator must be removed and the mode door mechanically checked for proper operation. Typical problems that prevent door movement include screws dropped in the A/C unit or warped doors. Replace any part that is found defective. Anytime the voltage to the BCM is interrupted for less than 2 minutes or voltage drops below approximately 10.0 volts (battery disconnected, etc.), it may be necessary to recalibrate the mode door. This can be done by using the DRB, MDS machine or removing the IOD (M1) fuse for 10 seconds, reinstall it and then start the engine. Diagnostic Strategies ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 1931 Body Control Module: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRBIII DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform VEHICLE COMMUNICATION TEST 1A. DRBIII Error Messages DRBIII ERROR MESSAGE Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 1932 Body Control Module: Service and Repair JUNCTION BLOCK REMOVAL Junction Block/BCM Location The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. Junction Block and Body Control Module assemblies are located on the driver's side of the vehicle. 1. Open the front driver's door and remove end cap. 2. Remove center bezel. 3. Remove instrument cluster hood. 4. Remove silencer. 5. Remove wire harness connectors from Junction Block. 6. Remove Junction Block three mounting screws. 7. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 8. Disconnect BCM wire connectors and remove the assembly. 9. Remove Junction Block/BCM from vehicle. INSTALLATION - For installation, reverse the above procedures. Ensure that the wire terminals and connectors are in good condition and connectors are properly installed. BODY CONTROL MODULE REMOVAL 1. The Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 2. Remove the two BCM attaching screws and release the two BCM locking latches from the Junction Block. 3. Disconnect BCM from the Junction Block. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 1933 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII (diagnostic read-out box) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Specifications Powertrain Control Module: Specifications PCM Mounting screw torque ............................................................................................................... .......................................................... 4 Nm (35 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: Component Locations Fig. 16 Power Distribution Center (PDC) The Powertrain Control Module (PCM) is located in the left front engine compartment close to the transmission control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1939 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1942 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1943 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1944 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1945 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1946 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1947 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1948 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1949 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1950 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1951 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1952 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1953 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1954 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1955 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1956 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1957 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1958 Powertrain Control Module: Connector Views Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1959 PCM Connector View Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 1960 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. 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 because of corrosion. - 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. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Description and Operation > Component Description Powertrain Control Module: Description and Operation Component Description Fig.9 Power Distribution Center (PDC) The PCM regulates the ignition system. The PCM supplies battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM controls ignition timing by turning on and off a transistor in the distributor. During the crank-start period the PCM maintains spark advance at 9° BTDC. During engine operation the following inputs determine the amount of spark advance provided by the PCM. Intake air temperature. - Coolant temperature. - Engine RPM. - Intake manifold vacuum. The PCM also regulates the fuel injection system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Description and Operation > Component Description > Page 1963 Powertrain Control Module: Description and Operation PCM Battery Feed CIRCUIT OPERATION Circuit A14 is used to provide a constant battery feed to the Powertrain Control Module (PCM). This circuit originates in the Power Distribution Center (PDC) and is protected by a 20 Amp fuse located in cavity 5. It is also spliced and provides power for the Automatic Shut Down (ASD) relay, coil and contact sides. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Description and Operation > Component Description > Page 1964 Powertrain Control Module: Description and Operation Power (Device) Ground Helpful Information Circuit Z12 which supplies a ground for the PCM high current drivers, terminates at the left strut tower. If the system loses ground for the Z12 circuit the vehicle will not operate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Description and Operation > Component Description > Page 1965 Powertrain Control Module: Description and Operation System Operation SYSTEM OPERATION Powertrain Control Module The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. See Charging System/Testing and Inspection/Procedures/On-board Diagnostic System Test. The PCM cannot be repaired and must be replaced if faulty. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Component Tests and General Diagnostics Powertrain Control Module: Component Tests and General Diagnostics Component Testing Testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Diagnostic Charts For Trouble Code charts see Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts. See: Computers and Control Systems/Testing and Inspection SBEC Testing No specific procedures are provided to diagnose the SBEC by itself. Please See: Computers and Control Systems, Testing and Inspection. SBEC failure is determined as a result of a related system failure. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Page 1968 Powertrain Control Module: Service and Repair Fig. 33 Auxiliary Jumper Terminal POWERTRAIN CONTROL MODULE SERVICE The PCM attaches to a bracket between the air cleaner housing and Power Distribution Center (PDC) Fig. 33. REMOVAL 1. Disconnect negative cable from auxiliary jumper terminal Fig. 33. 2. Disconnect both 40-way connectors from PCM. Fig. 34 PCM Bracket Screws 3. Remove screws attaching PCM to bracket Fig. 34. 4. Lift PCM up to remove it from vehicle. INSTALLATION 1. Install PCM. Tighten mounting screws. 2. Attach both 40-way connectors to PCM. 3. Connect negative cable to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1972 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1973 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1974 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1975 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1976 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, generator field, electronic ignition coil and the heating elements in the oxygen sensors. Refer to Diagrams/Electrical for circuit information. The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. OPERATION The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. When the ignition switch is in On or Start, the PCM momentarily turns on the ASD relay. The PCM also monitors the ASD relay output voltage. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. While the relay is on the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the PDC Fig. 25. The inside top of the PDC cover has label showing relay and fuse identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1977 Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Power for the coil and contact side of the relay is provided by circuit A14. This circuit is HOT at all times and protected by a 20 amp fuse located in cavity 5 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the relay on circuit K51. This circuit connects to cavity 67 of the PCM connector. When the relay is energized, the contacts internal to the relay close connecting circuits A14 and A142. The A142 circuit is spliced and provides power to the fuel injectors, generator, electronic EGR transducer solenoid, and the ignition coil. The A142 circuit is also spliced and connects to the PCM connector, cavity 6. This input is used for ASD sense by the PCM. HELPFUL INFORMATION Check the 20 amp fuse located in cavity 5 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in cavity 5 of the PDC Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 1980 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD Relay Test Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 1981 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 1 ASD And Fuel Pump Relay Terminals OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Electrical Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 1988 Fuel Pump Relay: Diagrams Power Distribution Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 1989 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 1990 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 1991 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 1992 Fuel Pump Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) FUEL PUMP RELAY - PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. Power for the solenoid is supplied through a 10A fuse in the Junction Block. The contacts are supplied power through a 20A fuse in the PDC. Refer to Diagrams/Electrical for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. The fuel pump relay is located in the PDC Fig. 25. The inside top of the PDC cover has a label showing relay and fuse location. Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 1993 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 1994 Fuel Pump Relay: Testing and Inspection Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1998 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1999 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2000 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2001 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2002 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, generator field, electronic ignition coil and the heating elements in the oxygen sensors. Refer to Diagrams/Electrical for circuit information. The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. OPERATION The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. When the ignition switch is in On or Start, the PCM momentarily turns on the ASD relay. The PCM also monitors the ASD relay output voltage. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. While the relay is on the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the PDC Fig. 25. The inside top of the PDC cover has label showing relay and fuse identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2003 Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Power for the coil and contact side of the relay is provided by circuit A14. This circuit is HOT at all times and protected by a 20 amp fuse located in cavity 5 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the relay on circuit K51. This circuit connects to cavity 67 of the PCM connector. When the relay is energized, the contacts internal to the relay close connecting circuits A14 and A142. The A142 circuit is spliced and provides power to the fuel injectors, generator, electronic EGR transducer solenoid, and the ignition coil. The A142 circuit is also spliced and connects to the PCM connector, cavity 6. This input is used for ASD sense by the PCM. HELPFUL INFORMATION Check the 20 amp fuse located in cavity 5 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in cavity 5 of the PDC Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 2006 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD Relay Test Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 2007 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 1 ASD And Fuel Pump Relay Terminals OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Electrical Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions > Page 2013 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located on the rear side of the front bumper beam. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the Powertrain Management/Computers and Control Systems/Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: 1. Disconnect the sensor from the engine harness. 2. Attach ohmmeter leads to the wire terminals of the sensor. 3. At room temperature of 25 °C (75 - 80°F), an ohmmeter reading of 9 K to 11 K ohms should be observed. 4. If reading is above or below the specification, replace the sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2016 Battery Temperature Sensor: Service and Repair REMOVAL 1. Raise vehicle on host. 2. Remove screw from sensor. 3. Disconnect electrical connector from sensor. INSTALLATION 1. Connect electrical connector to sensor. 2. Install screw and tighten. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) Camshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2020 Camshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2021 Camshaft Position Sensor: Description and Operation Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. OPERATION This vehicle is equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. The distributor is also equipped with an internal camshaft position (fuel sync) sensor Fig. 2. This sensor provides fuel injection synchronization and cylinder identification to the PCM. The camshaft position sensor contains a hall effect device called a sync signal generator. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the shutter enters the sync signal generator, the interruption of magnetic field causes the voltage to switch high. This causes a sync signal of approximately 5 volts. When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts. Since the shutter rotates at half crankshaft speed, it may take one engine revolution during cranking for the PCM to determine the position of piston number 6. NO CAM SIGNAL AT PCM FAULT MESSAGE Purpose The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. Operation The sensor is provided with 12 volts from the fused ignition switch output circuit and the powertrain control module supplies a sensor ground. The CMP sensor has a 5 volt pull-up from the PCM. The sensor signal is created when the distributor's pulse ring is rotated past the camshaft position sensor. When Monitored: The crankshaft position sensor signal trouble code is not set. With the ignition in either the start or run position and battery voltage between 4 and 15 volts. Set Condition: Too many crankshaft position sensor signals detected without any camshaft position sensor signal Possible Causes: Open fused ignition switch output circuit (12V) - Open sensor ground - Damaged pulse ring - Failed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2022 - Failed PCM - Inoperative distributor drive - Broken timing belt - Connector terminals - Connector wires Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 2025 Camshaft Position Sensor: Service and Repair The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant temperature sensor torque ..................................................................................................... .......................................................... 27 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2029 Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor And Oil Pressure Switch Locations Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2030 Engine Coolant Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2031 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor is installed in the housing between the filler neck and thermostat Fig. 7. The sensor provides an input voltage to the PCM. The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emissions and improve driveability - Because spark advance changes at different engine operating temperatures during warm-up, all spark advance testing should be done with the engine fully warmed. The PCM demands slightly richer air-fuel mixtures and higher idle speeds until the engine reaches normal operating temperature. The engine coolant sensor input is also used for radiator fan control. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. This sensor input is also used for the instrument cluster coolant temperature gauge. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 4 Engine Coolant Temperature Sensor 1. With key off, disconnect wire connector from engine coolant temperature sensor Fig. 4. 2. Connect one lead of ohmmeter to one terminal of engine coolant temperature sensor. 3. Connect the other lead of ohmmeter to remaining terminal of engine coolant temperature sensor. The ohmmeter should read as follows; - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F, ohmmeter should read approximately 7,000 to 13,000 ohms. 4. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between connector terminal 43 and the sensor harness connector. Refer to Wiring Diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Component Testing > Page 2034 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Testing and Inspection > Page 2035 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. REMOVAL 1. Drain cooling system until coolant level is below engine coolant temperature sensor. Refer to Cooling System. 2. Disconnect electrical connector from sensor. 3. Remove sensor from engine. INSTALLATION 1. Install ECT sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor screw torque ................................................................................................................................................... 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2039 Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2040 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2041 Crankshaft Position Sensor: Description and Operation Fig. 5 Timing Slots Fig. 3 Crankshaft Position Sensor--Adjustable Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2042 Fig 12 Crankshaft Position Sensor Location -- Typical OPERATION The crankshaft position sensor Fig. 3 detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots Fig. 5. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. - The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. - It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The sensor connector has a Christmas tree attached to the heater tube bracket. - The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On automatic transmission vehicles this circuit is spliced and provides an input to the Transmission Control Module (TCM). The PCM provides a ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. HELPFUL INFORMATION The K7 circuit supplies 8 volts to the distributor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 9 Crankshaft Position Sensor REMOVAL 1. Remove speed control servo from driver's side strut tower. 2. Remove crankshaft position sensor retaining bolt Fig. 9. 3. Pull crankshaft position sensor straight up out of the transaxle housing. 4. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. INSTALLATION - ADJUSTABLE Some vehicles may be equipped with an adjustable crankshaft position sensor. This can be identified by an elongated mounting hole in the sensor. Fig. 10 Crankshaft Position Sensor And Spacer If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor Fig. 10. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 2. Connect crankshaft position sensor electrical connector to the wiring harness connector. 3. Attach connector to heater tube bracket. 4. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. INSTALLATION - NON-ADJUSTABLE 1. Install sensor in transaxle. 2. Install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. 4. Attach connector to heater tube bracket. 5. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2047 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel level input comes across the CCD bus from the body control module. this input is used for the Fuel System and Misfire Monitors. If the fuel level is below approximately 1/16th of a tank the Fuel System and Misfire monitors will be disabled. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake air temperature sensor torque ....................................................................................................................................................... 11.5 Nm (100 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2054 Fig. 21 Intake Air Temperature Sensor And MAP Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2055 Intake Air Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2056 Intake Air Temperature Sensor: Description and Operation Fig. 11 Intake Air Temperature Sensor And MAP Sensor PURPOSE The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. OPERATION The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. - At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to cavity 37 of the PCM connector. The IAT sensor threads into the intake manifold Fig. 11. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. The K21 circuit connects to cavity 37 of the PCM connector. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground path for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Component Testing Intake Air Temperature Sensor: Testing and Inspection Component Testing Fig. 5 Intake Air Temperature Sensor And MAP Sensor NOTE: To perform a complete test of this sensor and its circuit, SEE System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from the intake air temperature sensor Fig. 5. 2. Connect a high input impedance (digital) volt-ohmmeter to the sensor terminals. The ohmmeter should read as follows: - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 37 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. Refer to Electrical Diagrams for circuit information. - If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2059 Intake Air Temperature Sensor: Service and Repair Fig. 21 Intake Air Temperature Sensor And MAP Sensor The intake air temperature sensor threads into the intake manifold plenum Fig. 21. REMOVAL 1. Remove electrical connector from sensor. 2. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2064 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP sensor torque .............................................................................................................................. ....................................................... 3.4 Nm (30 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2065 Fig. 21 Intake Air Temperature Sensor And MAP Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2066 Map Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2067 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 5 Intake Air Temperature Sensor And MAP Sensor OPERATION The MAP sensor reacts to absolute pressure in the intake manifold and provides an input voltage to the PCM. The PCM interprets the MAP sensor input as engine load. The input voltage level supplies the PCM with information relating to ambient barometric pressure during engine start-up (cranking) and engine load while its operating. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. The PCM supplies 5 volts direct current to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. At key on, before the engine is started, the PCM determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The sensor is mounted on the intake manifold Fig. 1. The sensor is connected to the throttle body or intake manifold with a vacuum hose and to the PCM electrically CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Manifold Absolute Pressure (MAP) sensor Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides a ground path for the MAP signal (circuit K1) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 30 MAP Sensor Connector NOTE: Complete testing of this component and its circuit is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 3 (Fig. 30). - With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. - The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. - If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (+/0.5V). Five volts (+/-0.5V) should also be at terminal 43 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. NOTE: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2070 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 volts to the A/C pressure switch and the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Throttle position sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2071 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 21 Intake Air Temperature Sensor And MAP Sensor The MAP sensor attaches to the intake manifold plenum Fig. 21. REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seal. 2. Tighten mounting screws to 3.4 Nm (30 in. lbs.) torque. 3. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle Technical Service Bulletin # 18-01-98 Date: 980116 MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle NO: 18-01-98 GROUP: Driveability DATE: Jan. 16, 1998 SUBJECT: MIL Illumination with Hex Code $3E, Possible Sags/Hesitations/Rough Idle MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: MIL illumination with hex code $3E - UPSTREAM O2 SENSOR SHORTED TO VOLTAGE along with possible symptoms of sags/hesitation or rough idle. NOTE: HEX CODE $3E MUST BE SEEN TO PERFORM THIS REPAIR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-94-TF-91 0.4 Hrs. FAILURE CODE: P8 - New Part 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 DTC $3E is present, follow the diagnostic procedure in the applicable diagnostic manual. If no apparent reason is found for the DTC, perform the Repair Procedure. Parts/Equipment Required 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable AR (1) 05010885AA Kit, Oxygen Sensor Jumper (4-cyl & 96/97 6-cyl) AR (1) 05010934AA Kit, Oxygen Sensor Jumper (1995 6-cyl) AR 04778570 Heat Shrink Tubing AR (1) 04778138 Tape, Cloth Underhood Electrical 1 NPN Soldering Iron 1 NPN Rosin Core Solder Repair Procedures This bulletin involves cutting and splicing a jumper from the oxygen sensor(s) to the powertrain control module. Single Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector and disconnect it. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2080 3. Identify the sensor ground terminal. For 1997 models it is terminal No. 3, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). For 1995/1996 models it is terminal No. 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1997 connectors use a rear secondary lock latch at the rear side of the connector. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 3 by carefully pulling from the rear while spreading the two locking fingers. 1995/1996 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal No. 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out from the rear. 5. Choose the terminal on the end of the repair lead p/n 05010885AA that matches the removed terminal. Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. NOTE: THE TERMINAL END ON THE OPPOSITE END OF THE NEW LEAD IS FOR THE OTHER APPLICABLE YEAR VEHICLES. THIS TERMINAL MUST BE CLIPPED OFF. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2081 8. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 9. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 10. Cut the k4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 11. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. 12. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 13. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 14. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 15. Reconnect the battery negative cable. 16. Verify the wiring repair by running the oxygen sensor test with the DRB III. Double Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector # 1 and disconnect it. 3. Identify the sensor ground terminal. For 1995 models, it is terminal # 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1995 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal # 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out form the rear. 5. Choose the terminal on the end of the repair lead p/n 05010934AA that has the longer length of wire from the Y splice (1100 mm). Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Repeat steps 3 through 6 for the upstream oxygen sensor No. 2, using the other lead from the Y spliced repair jumper. 8. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. 9. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 10. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 11. Cut the K4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2082 13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 14. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 15. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 16. Reconnect the battery negative cable. 17. Verify the wiring repair by running the oxygen sensor test with the DRB III. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle Technical Service Bulletin # 18-01-98 Date: 980116 MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle NO: 18-01-98 GROUP: Driveability DATE: Jan. 16, 1998 SUBJECT: MIL Illumination with Hex Code $3E, Possible Sags/Hesitations/Rough Idle MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: MIL illumination with hex code $3E - UPSTREAM O2 SENSOR SHORTED TO VOLTAGE along with possible symptoms of sags/hesitation or rough idle. NOTE: HEX CODE $3E MUST BE SEEN TO PERFORM THIS REPAIR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-94-TF-91 0.4 Hrs. FAILURE CODE: P8 - New Part 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 DTC $3E is present, follow the diagnostic procedure in the applicable diagnostic manual. If no apparent reason is found for the DTC, perform the Repair Procedure. Parts/Equipment Required 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable AR (1) 05010885AA Kit, Oxygen Sensor Jumper (4-cyl & 96/97 6-cyl) AR (1) 05010934AA Kit, Oxygen Sensor Jumper (1995 6-cyl) AR 04778570 Heat Shrink Tubing AR (1) 04778138 Tape, Cloth Underhood Electrical 1 NPN Soldering Iron 1 NPN Rosin Core Solder Repair Procedures This bulletin involves cutting and splicing a jumper from the oxygen sensor(s) to the powertrain control module. Single Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector and disconnect it. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2088 3. Identify the sensor ground terminal. For 1997 models it is terminal No. 3, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). For 1995/1996 models it is terminal No. 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1997 connectors use a rear secondary lock latch at the rear side of the connector. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 3 by carefully pulling from the rear while spreading the two locking fingers. 1995/1996 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal No. 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out from the rear. 5. Choose the terminal on the end of the repair lead p/n 05010885AA that matches the removed terminal. Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. NOTE: THE TERMINAL END ON THE OPPOSITE END OF THE NEW LEAD IS FOR THE OTHER APPLICABLE YEAR VEHICLES. THIS TERMINAL MUST BE CLIPPED OFF. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2089 8. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 9. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 10. Cut the k4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 11. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. 12. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 13. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 14. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 15. Reconnect the battery negative cable. 16. Verify the wiring repair by running the oxygen sensor test with the DRB III. Double Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector # 1 and disconnect it. 3. Identify the sensor ground terminal. For 1995 models, it is terminal # 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1995 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal # 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out form the rear. 5. Choose the terminal on the end of the repair lead p/n 05010934AA that has the longer length of wire from the Y splice (1100 mm). Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Repeat steps 3 through 6 for the upstream oxygen sensor No. 2, using the other lead from the Y spliced repair jumper. 8. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. 9. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 10. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 11. Cut the K4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2090 13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 14. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 15. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 16. Reconnect the battery negative cable. 17. Verify the wiring repair by running the oxygen sensor test with the DRB III. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2091 Oxygen Sensor: Specifications - After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. - If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite (R) 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. - Tighten the sensor to 28 Nm (20 ft. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2094 Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2095 Fig 12 Upstream Heated Oxygen Sensor 1/1 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Front Upstream Oxygen Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor > Page 2098 Downstream Oxygen Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2099 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2100 Oxygen Sensor: Description and Operation Fig 12 Upstream Heated Oxygen Sensor 1/1 OPERATION As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic converter, one downstream of the converter. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop. the PCM adjusts injector pulse width based on preprogrammed (fixed values and inputs from other sensors. The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 12). Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2101 DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 13). The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. CIRCUIT OPERATION Circuit A14 is connected to the BUS bar in the Power Distribution Center (PDC), which connects to battery voltage. The contact side of the Automatic Shut-Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse, located in cavity 5 of the PDC, protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM. The A142 circuit also splices to cavity 6 of the PCM connector. The input by circuit A142 tells the PCM that the ASD relay is energized. The A142 circuit supplies voltage for the upstream heated oxygen sensor and circuit F142 supplies voltage to the downstream heated oxygen sensor. The F142 circuit is protected by a 10 Amp fuse located in cavity 1 of the PDC. Power for the fuse is supplied by circuit A142. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the downstream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream (left) and downstream (right) heated oxygen sensor signals (circuits K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Circuit Z1 provides the ground path for the heater circuits in the sensors. This ground terminates at the right frame rail. Circuit K4 splices to supply ground for the signals for the following: Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Vehicle speed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, distributor, ASD relay, generator, and the EGR solenoid. The PCM controls the ground path for each of the components powered by circuit A142. Circuit K4 splices to supply ground for the signals for the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Vehicle speed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2104 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 5 and 7 ohms. NOTE: This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. NOTE: Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS ONLY (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 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 connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See, sensor heating element test. 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. NOTE: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2105 Oxygen Sensor: Service and Repair Fig 89 Upstream Oxygen Sensor REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector from sensor. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 89). INSTALLATION 1. After removing the sensor the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. - If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. - Tighten the sensor to 28 Nm (20 ft lb) torque. 2. Connect electrical connector to sensor. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2106 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revision NUMBER: 26-10-96 GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus, Stratus & Breeze - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs 8W-80-44 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2111 8W-80-45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2112 8W-80-46 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2113 8W-80-47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2116 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2117 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2118 Power Steering Pressure Switch: Description and Operation Fig. 21 Power Steering Pressure Switch PURPOSE On some vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. OPERATION The pressure switch improves vehicle idle quality, by maintaining required engine idle speed when necessary, do to increased pressure in the power steering system. This increased pressure will slow down the power steering pump which will decrease engine idle speed. The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear on vehicle's requiring its usage. When power steering pump pressure exceeds 4137 kPa (600 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z1 provides a ground for the power steering pressure switch. The ground is terminated at the left strut tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2119 Power Steering Pressure Switch: Service and Repair REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on the back side of the power steering gear. 4. Remove the vehicle's wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Output Voltage At idle ................................................................................................................................................... ...................................... greater than 0.6 volts At wide open throttle (WOT) ........................................................................................................................................................... less than 4.5 volts Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2124 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2125 Fig. 23 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2126 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2127 Throttle Position Sensor: Description and Operation Fig. 23 Throttle Position Sensor PURPOSE Along with inputs from other sensors, the PCM uses TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the PCM) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to a maximum of 3.7 volts at wide open throttle. The throttle position sensor mounts to the side of the throttle body Fig. 23. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides a ground path for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 Volts to the A/C pressure switch and the map sensor. On automatic transmission vehicles, circuit K22 is spliced and provides an input to the Transmission Control Module (TCM). Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2130 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be greater than 0.6 volts. - At wide open throttle, TPS output voltage should be less than 4.5 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2131 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2132 Throttle Position Sensor: Service and Repair Fig. 37 Throttle Position Sensor The TPS attaches to the side of the throttle body Fig. 37. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and TPS. 3. Remove throttle body. 4. Remove TPS mounting screws. 5. Remove throttle position sensor. Fig. 38 Indexing Throttle Position Sensor INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 38. - The socket has two tabs inside it. The throttle shaft rests against the tabs. - When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. - The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. - Tighten mounting screws to 2 Nm (17 in. lbs.) torque. NOTE: After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 2. Install throttle body to intake manifold. 3. Attach electrical connectors to idle air control motor and throttle position sensor. 4. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2141 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2142 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2143 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2149 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2150 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2155 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2156 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2157 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2163 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2164 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2165 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2168 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2169 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2170 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2171 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2172 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2178 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2179 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2180 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2181 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2182 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2183 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2184 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2185 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2186 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2187 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2188 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2189 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2190 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2191 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2192 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2193 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2194 Vehicle Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2195 Vehicle Speed Sensor: Description and Operation TRANSMISSION CONTROL MODULE -- AUTO TRANS -- PCM INPUT The Transmission Control Module (TCM) supplies 3 inputs to the PCM: Vehicle Speed (road speed) - Torque Management - Gear Position VEHICLE SPEED The TCM supplies vehicle speed and distance traveled inputs to the PCM. From these inputs and the throttle position sensor input, the PCM determines when a deceleration condition occurs. TORQUE MANAGEMENT The PCM receives a torque management input from the TCM. The PCM receives the input when the transmission shifts gears. In response, the PCM shuts off a number of fuel injectors when the transmission shifts gears. Fig. 24 Vehicle Speed Sensor--Manual Transmission VEHICLE SPEED SENSOR - PCM INPUT (MANUAL TRANSMISSION) The vehicle speed sensor is located in the transmission extension housing Fig. 24. The sensor input is used by the PCM to determine vehicle speed and distance traveled, manual transmission only. Refer to Transmission Control Module for automatic transmission. The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate the following functions or systems: Speedometer - Speed Control - Daytime Running Lights (Canadian Vehicles Only) - Open Throttle IAC position. CIRCUIT OPERATION On vehicles equipped with the manual transmission, a Vehicle Speed Sensor (VSS) located in the transmission is used. Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the VSS. The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7, from the VSS, provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides a ground path for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 is spliced and provides an input to the Body Control Module (BCM) for vehicle speed. Circuit K4 splices to supply ground for the signals for the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2198 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 100). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor. 2. Install mounting bolt. 3. Connect electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Output Voltage At idle ................................................................................................................................................... ...................................... greater than 0.6 volts At wide open throttle (WOT) ........................................................................................................................................................... less than 4.5 volts Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2204 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2205 Fig. 23 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2206 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2207 Throttle Position Sensor: Description and Operation Fig. 23 Throttle Position Sensor PURPOSE Along with inputs from other sensors, the PCM uses TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the PCM) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to a maximum of 3.7 volts at wide open throttle. The throttle position sensor mounts to the side of the throttle body Fig. 23. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides a ground path for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 Volts to the A/C pressure switch and the map sensor. On automatic transmission vehicles, circuit K22 is spliced and provides an input to the Transmission Control Module (TCM). Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2210 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be greater than 0.6 volts. - At wide open throttle, TPS output voltage should be less than 4.5 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2211 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2212 Throttle Position Sensor: Service and Repair Fig. 37 Throttle Position Sensor The TPS attaches to the side of the throttle body Fig. 37. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and TPS. 3. Remove throttle body. 4. Remove TPS mounting screws. 5. Remove throttle position sensor. Fig. 38 Indexing Throttle Position Sensor INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 38. - The socket has two tabs inside it. The throttle shaft rests against the tabs. - When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. - The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. - Tighten mounting screws to 2 Nm (17 in. lbs.) torque. NOTE: After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 2. Install throttle body to intake manifold. 3. Attach electrical connectors to idle air control motor and throttle position sensor. 4. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) Camshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2217 Camshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2218 Camshaft Position Sensor: Description and Operation Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. OPERATION This vehicle is equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. The distributor is also equipped with an internal camshaft position (fuel sync) sensor Fig. 2. This sensor provides fuel injection synchronization and cylinder identification to the PCM. The camshaft position sensor contains a hall effect device called a sync signal generator. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the shutter enters the sync signal generator, the interruption of magnetic field causes the voltage to switch high. This causes a sync signal of approximately 5 volts. When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts. Since the shutter rotates at half crankshaft speed, it may take one engine revolution during cranking for the PCM to determine the position of piston number 6. NO CAM SIGNAL AT PCM FAULT MESSAGE Purpose The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. Operation The sensor is provided with 12 volts from the fused ignition switch output circuit and the powertrain control module supplies a sensor ground. The CMP sensor has a 5 volt pull-up from the PCM. The sensor signal is created when the distributor's pulse ring is rotated past the camshaft position sensor. When Monitored: The crankshaft position sensor signal trouble code is not set. With the ignition in either the start or run position and battery voltage between 4 and 15 volts. Set Condition: Too many crankshaft position sensor signals detected without any camshaft position sensor signal Possible Causes: Open fused ignition switch output circuit (12V) - Open sensor ground - Damaged pulse ring - Failed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2219 - Failed PCM - Inoperative distributor drive - Broken timing belt - Connector terminals - Connector wires Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 2222 Camshaft Position Sensor: Service and Repair The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor screw torque ................................................................................................................................................... 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2226 Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2227 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2228 Crankshaft Position Sensor: Description and Operation Fig. 5 Timing Slots Fig. 3 Crankshaft Position Sensor--Adjustable Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2229 Fig 12 Crankshaft Position Sensor Location -- Typical OPERATION The crankshaft position sensor Fig. 3 detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots Fig. 5. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. - The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. - It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The sensor connector has a Christmas tree attached to the heater tube bracket. - The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On automatic transmission vehicles this circuit is spliced and provides an input to the Transmission Control Module (TCM). The PCM provides a ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. HELPFUL INFORMATION The K7 circuit supplies 8 volts to the distributor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 9 Crankshaft Position Sensor REMOVAL 1. Remove speed control servo from driver's side strut tower. 2. Remove crankshaft position sensor retaining bolt Fig. 9. 3. Pull crankshaft position sensor straight up out of the transaxle housing. 4. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. INSTALLATION - ADJUSTABLE Some vehicles may be equipped with an adjustable crankshaft position sensor. This can be identified by an elongated mounting hole in the sensor. Fig. 10 Crankshaft Position Sensor And Spacer If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor Fig. 10. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 2. Connect crankshaft position sensor electrical connector to the wiring harness connector. 3. Attach connector to heater tube bracket. 4. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. INSTALLATION - NON-ADJUSTABLE 1. Install sensor in transaxle. 2. Install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. 4. Attach connector to heater tube bracket. 5. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2234 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2244 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2245 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2246 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2247 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2248 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2249 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2250 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2251 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2252 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2253 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2254 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2255 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2261 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2262 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2263 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2264 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2265 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2266 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2267 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2268 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2269 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2270 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2271 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 2272 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2273 Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2274 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start Lock Cylinder Retaining Tab REMOVAL 1. Disconnect negative cable from auxillary jumper terminal -- on driver's side strut tower. 3. Remove upper steering column shroud. 3. Pull lower shroud down far enough to access lock cylinder retaining tab. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to RUN position (retaining tab on lock cylinder can be depressed). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2275 Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the RUN position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the OFF position. Remove the key. 5. Install steering column shrouds. 5. Connect negative cable to auxillary battery terminal on shock tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Adapter Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 miles ................................................................................ .............................................................................................. 450 - 1,100 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 500 - 1,100 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2284 Idle Speed: Testing and Inspection Fig. 35 Purge Hose 1. Turn ignition key to Off. 2. Disconnect the PCV valve hose from the intake manifold nipple. Cap the PCV vacuum nipple. 3. Disconnect purge hose from the nipple on the throttle body Fig. 35. Fig. 37 Orifice6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) to the purge nipple on the throttle body Fig. 37. 5. Ensure that all accessories are off. 6. Connect the DRB Scan Tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB Scan Tool, access Minimum Airflow Idle Speed. 9. The following will then occur: - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB Scan Tool displays engine RPM 10. If idle RPM is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. - Below 1,000 miles ............................................................................................................................. ........................................... 450 - 1,100 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 500 - 1,100 rpm 11. If idle RPM is above specifications, use the DRB Scan Tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves. DO NOT let Mopar (TM) Parts Cleaner come in contact with eyes or skin. DO NOT ingest the cleaner. Wash thoroughly after using cleaner. a. Remove the throttle body from engine. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar (TM) Parts Cleaner. Only use Mopar (TM) Parts Cleaner to clean the throttle body. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2285 c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB Scan Tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Housing And Element REMOVAL 1. Unfasten clasps on rear of air cleaner housing cover. Lift cover off air cleaner housing. Air Cleaner Housing And Element 2. Remove filter element. 3. If necessary clean the inside of the air cleaner housing. INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps in place. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2294 Fuel Pressure Release: Service and Repair Fig. 2 Releasing Fuel Pressure Fig. 1 Fuel Pressure Test Port--Typical CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock. 1. Disconnect the fuel rail electrical harness from the engine harness. Refer to Diagrams/Electrical. 2. Connect one end of a jumper wire to the A142 circuit terminal of the fuel rail harness connector. 3. Connect the other end of the jumper wire to a 12 volt power source. 4. Connect one end of a jumper wire to a good ground source. 5. Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector. Repeat procedure for 2 to 3 injectors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Fig. 1 Spark Plug Cable Routing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Fig. 1 Spark Plug Cable Routing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 560 Ohms per Inch 3,000 Ohms per Foot 6,700 Ohms per Foot Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2305 Ignition Cable: Description and Operation Spark Plug cables are sometimes referred to as secondary ignition wires. They transfer electrical current from the distributor, to individual spark plugs at each cylinder. They transfer electrical current from the distributor to individual spark plugs at each cylinder. The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Check the spark plug cable connections for good contact at the coil and distributor cap towers and at the spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil and distributor cap towers and spark plug cover should fit tight around spark plug insulators. - Loose cable connections can cause ignition malfunctions by permitting water to enter the towers, corroding, and increasing resistance. 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. Clean high tension cables with a cloth moistened with a non-flammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2308 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from cable clips. 3. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. 4. Connect the ohmmeter between the spark plug end terminal and the corresponding electrode inside the cap. - Make sure ohmmeter probes are 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 the same manner. To test the connection between the coil and distributor terminals: 1. Remove distributor cap. 2. Connect an ohmmeter between center contact in the cap and coil tower terminal. - Resistance should be approximately 5,000 ohms. - If resistance is not within tolerance, replace the cap. - If no problems are found, refer to Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 560 Ohms per Inch 3,000 Ohms per Foot 6,700 Ohms per Foot Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, 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. WARNING: The ignition system generates approximately 32,000 volts. Personal injury could result from contact with this system. 2. With the 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. - Replace cracked, leaking or faulty cables. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 2309 Ignition Cable: Service and Repair Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 1 Spark Plug Cable Routing Remove the distributor cap and inspect the inside for: flash over - cracking of carbon button - lack of spring tension on carbon button - cracking of cap - burned, worn terminals - Also check for broken distributor cap towers. If any of these conditions are present the distributor cap and/or cables should be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection > Page 2314 Distributor Cap: Service and Repair Fig. 1 Spark Plug Cable Routing When replacing the distributor cap, transfer cables from the original cap to the new cap one at a time. Ensure each cable is installed into the corresponding tower of the new cap. Fully seat the wires into the towers. If necessary refer to the appropriate engine firing order diagram Fig. 1. Light scaling of the terminals can be cleaned with a sharp knife. If the terminals are heavily scaled, replace the distributor cap. A cap that is greasy, dirty or has a powder-like substance on the inside should be cleaned with a solution of warm water and a mild detergent. Scrub the cap with a soft brush. Thoroughly rinse the cap and dry it with a clean soft cloth. Fig. 11 Distributor Cap Screws REMOVAL & INSTALLATION 1. Remove bolt holding air inlet resonator to intake manifold. 2. Loosen clamps holding air cleaner cover to air cleaner housing. 3. Remove PCV make-up air hose from air inlet tube. 4. Loosen hose clamp at throttle body. 5. Remove air inlet tube, resonator and air cleaner cover. 6. Remove EGR tube. 7. Remove spark plug cables from distributor cap. 8. Loosen distributor cap holddown screws and remove cap Fig. 11. 9. Transfer cables from old cap to new cap. The cap is numbered and so are the cables. 10. Install distributor cap. 11. Install distributor holddown washers and nuts. Tighten nuts to 13 Nm (9 ft lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Replace the rotor if: it is cracked - the tip is excessively burned or heavily scaled - the spring terminal does not have adequate tension Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection > Page 2318 Ignition Rotor: Service and Repair Fig. 11 Distributor Cap Screws Fig. 13 Distributor Rotor Button And Spring REMOVAL 1. Remove bolt holding air inlet resonator to intake manifold. 2. Loosen clamps holding air cleaner cover to air cleaner housing. 3. Remove PCV make-up air hose from air inlet tube. 4. Loosen hose clamp at throttle body. 5. Remove air inlet tube, resonator and air cleaner cover. 6. Remove EGR tube. 7. Remove spark plug cables from distributor cap. 8. Loosen distributor cap holddown screws and remove cap Fig. 11. 9. Mark the rotor position and remove rotor. The mark indicates where to position the rotor when reinstalling the distributor. 10. Inspect rotor for cracks or burned electrode. If any of these conditions exist, replace rotor. 11. Inspect rotor button for damage. Replace button and spring as required. Pull button and spring out of cap Fig. 13. 12. Reverse the removal steps for installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .............................. 0.965-1.092 mm (0.038-0.043 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2322 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................. RC10PYP4 Thread size .................................................... ................................................................................................................................................. (14 mm) 3/4 in. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2323 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 1,000 ohm tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Remove the spark plugs and examine them for burned electrodes and 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 recommended intervals. Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. This engine uses platinum spark plugs. CAUTION: Do not attempt to adjust the gap of a platinum plug. Cleaning of the platinum plug may damage the platinum tip. If carbon deposits must be removed, use a plug cleaner and complete cleaning within 20 seconds to protect electrode. Do not use a wire brush. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2326 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2327 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2328 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2329 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. 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 COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2330 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. 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 .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2331 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2332 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection NOTE: 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. - 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 -- SEE Spark Plug Condition. 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 0.038 - 0.043 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2333 Spark Plug Overheating Overheating is indicated by a 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. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2334 Spark Plug: Adjustments Fig 2 Platinum Pads Setting Spark Plug Electrode Gap CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge Fig. 3. - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. - Gap 0.038 to 0.043 in Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2335 Spark Plug: Service and Repair Fig. 3 Intake Manifold Sensors And Left Plenum Support SPARK PLUG SERVICE When replacing the spark plug and coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Do not attempt to adjust the gap of a platinum plug. Cleaning of the platinum plug may damage the platinum tip. If carbon deposits must be removed, use a plug cleaner and complete cleaning within 20 seconds to protect electrode. Do not use a wire brush. SPARK PLUG REMOVAL Remove the spark plugs and examine them for burned electrodes and 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. SPARK PLUG REMOVAL - #2, #4 OR #6 Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1/2 turn and pulling straight back in a steady motion. 1. Prior to removing the spark plug spray compressed air around the spark plug hole and the area around the spark plug. 2. Remove the spark plug using a quality socket with a rubber or foam insert. 3. Inspect the spark plug condition. SPARK PLUG REMOVAL - #1, #3 OR #5 1. Disconnect negative cable from auxiliary jumper terminal. 2. Unplug connectors from MAP and intake air temperature sensors Fig. 3. 3. Remove plenum support bracket bolt located rearward of MAP sensor Fig. 3. 4. Remove bolt holding air inlet resonator to intake plenum Fig. 4. Fig. 4 Air Inlet Resonator 5. Loosen throttle body air inlet hose clamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2336 6. Release snaps holding air cleaner housing cover to housing. 7. Remove air cleaner cover and inlet hoses from engine. 8. Unplug TPS and idle air control motor connectors Figs. 5 and 6. 9. Pry retainer tab back on throttle cable and slide cable out of bracket Fig. 7. Remove cable from throttle lever. 10. Slide Speed control cable out of bracket, if equipped Fig. 7. Remove cable from throttle lever. 11. Remove EGR tube from intake plenum Fig. 8. Fig. 5 Throttle Sensor Position Sensor Fig. 6 Idle Air Control Module Fig. 7 Throttle Cable Attachment 12. Remove plenum support bracket bolt located rearward of EGR tube Fig. 8. 13. Remove bolts holding upper intake plenum and remove plenum. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2337 Fig. 8 EGR Tube And Right Manifold Support Bolt 14. Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1/2 turn and pulling straight back in a steady motion. 15. Prior to removing the spark plug spray compressed air around the spark plug hole and the area around the spark plug. 16. Remove the spark plug using a quality socket with a rubber or foam insert. 17. Inspect the spark plug condition. Fig 2 Platinum Pads SPARK PLUG INSTALLATION CAUTIONS: - Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. - Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. - Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicles original spark plugs that have been determined good. Do not apply anti-seize compound to new spark plugs. - Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the anti- seize compound doesn't make contact with the spark plug electrodes or ceramic insulator. - Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without following the correct procedures. - Always tighten spark plugs to the specified torque Over tightening can cause distortion resulting in a change in the spark plug gap. Over tightening can also damage the cylinder head. Tighten spark plugs to 28 Nm (20 ft. lbs.) torque. - Due to the engine packaging environment for these engines. extreme care should be used when installing the spark plugs to avoid cross threading problems. 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install ignition cables over spark plugs. 4. Install new gasket and position upper intake plenum. Tighten plenum bolts to 18 Nm (13 ft lb) torque. 5. Install bolts at plenum support brackets. Tighten bolts to 18 Nm (13 ft lb). 6. Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 in lb). 7. Install throttle and speed control (if equipped) cables. 8. Attach electrical connectors to sensors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2338 9. Tighten air inlet tube clamps to 2-4 Nm (20-30 in lb) torque. 10. Connect negative terminal to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION PRESSURE (at 250 - 400 RPM): Standard .............................................................................................................................................. ................................................. 1275 kPa (185 psi) Minimum ............................................................. ................................................................................................................................... 959 kPa (139 psi) COMPRESSION PRESSURE DIFFERENCE OF ALL CYLINDER: Maximum ............................................................................................................................................. ...................................................... 98 kPa (14 psi) VACUUM: Manifold ............................................................................................................................................... .......................................... 60 kPa (18 inches Hg) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2342 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications These engines are equipped with hydraulic lash adjusters designed to maintain zero lash at all times. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay -- PCM Output A/C Signal: Description and Operation A/C Clutch Relay -- PCM Output Fig. 25 Power Distribution Center (PDC) The PCM controls the air conditioning clutch relay ground circuit. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and power side of the relay. When the PCM senses low idle speeds or wide open throttle through the throttle position sensor, it removes the ground for the A/C compressor clutch relay. When the relay de-energizes, the contacts open preventing air conditioning clutch engagement. The air conditioning clutch relay is located in the PDC Fig. 25. The inside top of the PDC cover has a label showing relay and fuse location. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay -- PCM Output > Page 2351 A/C Signal: Description and Operation A/C Pressure Sensor Signal THEORY OF OPERATION: The A/C pressure sensor informs the PCM if the A/C system pressure is too low or too high. This information allows the PCM to determine if it can engage the compressor clutch. If the A/C system pressure is too low, the PCM will not engage the compressor clutch. - If the system pressure is too high, the PCM will disengage the compressor clutch and turn on the cooling fans to prevent the compressor head pressure from becoming too high. The sensor provides a signal to PCM cavity 42. The sensor receives a 5 volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. NAME OF CODE: A/C Pressure Sensor Volts Too Low When Monitored: With the ignition ON, the engine running, and the A/C relay energized. Set Condition: The A/C pressure sensor sensor signal at PCM cavity 42 goes below 0.7 volts. Possible Causes: Sensor signal shorted to ground - Sensor internally shorted - PCM failure NAME OF CODE: A/C Pressure Sensor Volts Too High When Monitored: With the ignition ON, the engine running, and the A/C relay energized. Set Condition: The A/C pressure sensor sensor signal at PCM cavity 42 goes above 4.9 volts. The sensor provides a signal to PCM cavity 42. The sensor receives a 5 volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: Sensor signal open - Sensor internally open - PCM failure Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay -- PCM Output > Page 2352 A/C Signal: Description and Operation A/C Requested Signal THEORY OF OPERATION: The A/C compressor clutch relay controls the 12-volt source for the A/C clutch. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM will adjust the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C select signal and adjustment of the idle speed has been implemented. NAME OF CODE: A/C Clutch Relay Circuit When Monitored: With the ignition key ON and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the A/C clutch relay control circuit. Possible Causes: Relay coil open or shorted - Fused ignition switch output circuit open - Compressor clutch relay control circuit open or shorted - Inoperative circuit driver in PCM Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake air temperature sensor torque ....................................................................................................................................................... 11.5 Nm (100 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2356 Fig. 21 Intake Air Temperature Sensor And MAP Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2357 Intake Air Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2358 Intake Air Temperature Sensor: Description and Operation Fig. 11 Intake Air Temperature Sensor And MAP Sensor PURPOSE The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. OPERATION The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. - At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to cavity 37 of the PCM connector. The IAT sensor threads into the intake manifold Fig. 11. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. The K21 circuit connects to cavity 37 of the PCM connector. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground path for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Component Testing Intake Air Temperature Sensor: Testing and Inspection Component Testing Fig. 5 Intake Air Temperature Sensor And MAP Sensor NOTE: To perform a complete test of this sensor and its circuit, SEE System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from the intake air temperature sensor Fig. 5. 2. Connect a high input impedance (digital) volt-ohmmeter to the sensor terminals. The ohmmeter should read as follows: - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 37 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. Refer to Electrical Diagrams for circuit information. - If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2361 Intake Air Temperature Sensor: Service and Repair Fig. 21 Intake Air Temperature Sensor And MAP Sensor The intake air temperature sensor threads into the intake manifold plenum Fig. 21. REMOVAL 1. Remove electrical connector from sensor. 2. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Antitheft Signal > Component Information > Description and Operation Antitheft Signal: Description and Operation On vehicles equipped with the optional Vehicle Theft Alarm (VTA) a set lamp is located in the cluster. This lamp is powered by the F33 circuit and protected by a 20 amp fuse located in cavity 7 of the junction block. The Body Control Module (BCM) controls the ground path for the lamp on the G69 circuit. When the system is ARMING and SET the BCM grounds the G69 circuit and the lamp illuminates. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions > Page 2368 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located on the rear side of the front bumper beam. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the Powertrain Management/Computers and Control Systems/Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: 1. Disconnect the sensor from the engine harness. 2. Attach ohmmeter leads to the wire terminals of the sensor. 3. At room temperature of 25 °C (75 - 80°F), an ohmmeter reading of 9 K to 11 K ohms should be observed. 4. If reading is above or below the specification, replace the sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2371 Battery Temperature Sensor: Service and Repair REMOVAL 1. Raise vehicle on host. 2. Remove screw from sensor. 3. Disconnect electrical connector from sensor. INSTALLATION 1. Connect electrical connector to sensor. 2. Install screw and tighten. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations ETACS-ECU ETACS-ECU Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 Body Control Module: Connector Views Body 20 Way Connector (At BCM) Engine 14 Way Connector (At BCM) Instrument Panel 10-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 Instrument Panel 22-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Body Control Module: Electrical Diagrams Body Control Module Wiring Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information Technician Safety Information WARNING: Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. 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. SERVICING SUB-ASSEMBLIES 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. Only those components with approved Service and Repair procedures in this database should be serviced. DRBIII Scantool Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRB if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. - Do not exceed the limits shown in the table above. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2408 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". 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 because of corrosion. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms Body Control Module: Application and ID Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The terms "gage" and "gauge" are used interchangeably Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms > Page 2411 Body Control Module: Application and ID Body Codes Defined JA ............................................................................................................................................................ Chrysler Cirrus, Plymouth Breeze, Dodge Stratus JX ......................................................................... ................................................................................................................... Chrysler Sebring Convertible Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Active Codes: A malfunction that is present now. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2414 ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2415 Body Control Module: Description and Operation Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2416 Body Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2417 Body Control Module: Description and Operation Climate Control Systems A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2418 Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2419 Active Codes: A malfunction that is present now. ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2420 protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Compass Mini-Trip Computer (CMTC) COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located on the right hand side of the instrument cluster. The CMTC is an electronic control module with a Vacuum Fluorescent Display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. Upon ignition the CMTC will turn on all of the segments in the display for 1 second then reverts to the last function screen that was displayed prior to the last ignition cycle. The functions that are available via actuation of the STEP switch are as follows: - Compass and Ambient Temperature - Average Trip Fuel Economy (AVE ECO) - Estimated Range (RANGE) - Present Fuel Economy (ECO) - Trip Odometer (ODO) - Elapsed Ignition On Time (ET) - Blank Screen (off) Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2421 NOTE: The terms "gage" and "gauge" are used interchangeably Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of four gauges, the status of seven indicator lamps, the status and dimming of the PRNDL indicator (VF display), and the dimming of cruise and low fuel lamps to the Mechanical Instrument Cluster (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run," or "start" positions. The PRNDL indicator works when the ignition is in the "off," "run," or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all PRNDL segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the tachometer exceeds 450 rpm. Power Door Lock System POWER DOOR LOCK SYSTEM When the Body Control Module (BCM) receives an input for a lock/unlock request (door lock switch, Remote Keyless Entry (RKE), or door key cylinder switch (w/VTSS only), it will ground the appropriate relay for a specified amount of time. For this vehicle all door lock relays are located inside the body control module and are not serviced separately. The door lock switches provide a variable voltage (Multiplexed (MUX) circuit) to the BCM and the BCM will respond to that command. If the conditions for door lock inhibit exist (key in ignition and left front door open), the BCM will not respond to a lock command. Other power door lock features: Automatic Door Locks This feature can be enabled/disabled by using either the DRB, MDS machine or customer key cycle method. When enabled, all the doors will lock when the vehicle reaches a speed greater than 15 MPH, all doors are closed and an increase of TPS signal is received by the PCM. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the vehicle speed accelerates above 15 MPH. Remote Keyless Entry (RKE) The body control module receives and decodes messages from the remote keyless entry transmitter. The remote keyless entry module is built into the BCM (premium) and is not serviced separately. When the lock button is pressed all doors will lock, horn will chirp, courtesy lamps will turn off and VTSS (if equipped) will arm. When the unlock button is pressed once, the left front door will unlock, courtesy lamps will light (if equipped w/illuminated entry) and VTSS (if equipped) will disarm. If the unlock button is pressed a second time (within 5 seconds of the first), all the other doors will unlock. Panic mode (if equipped with VTSS), is accomplished by pressing both lock and unlock buttons at the same time. 1997 JX transmitters have a separate panic button. This flashes the lights and sounds the horn but does not prevent the engine from running. The BCM will ignore all commands from the transmitter if the vehicle speed is over 15 MPH. This allows the engine to be running during warm up on cold days and then using the RKE to unlock the doors. The RKE software can store up to 4 transmitter codes. Rolling Code (97 JX only) The rolling code features changes part of the key fob (transmitter) message each time it is used. The key fob message and the receiver message increment together. Under certain conditions with a rolling code system (like pressing a button on the fob over 250 times outside of the receiver range) the receiver and transmitter can fall out of synchronization. By pressing specific buttons together, the system will re-synchronize. Radio-CCD RADIO - CCD NOTE: At the present time all 1997 CCD radios are not connected to the CCD bus. The audio systems used in the JX convertible will consist of one of the following radios: RAL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2422 RAL - Base radio with AM/FM stereo, bass and treble sliders only. RBS RBS - AM/FM stereo with cassette tape and CD changer option. Bass and treble controls. This radio may or may not be addressable with DRB. If it is equipped with the Premium Amplifier option (located under the passenger seat), it will be on the CCD bus. The Amplifier will determine whether the CCD connector in the back of the radio is wired. RBR RBR - AM/FM stereo with CD player only. Three band E.Q. Not connected to the bus. Not addressable with DRB. RAZ RAZ - AM/FM stereo with cassette and CD player incorporated into one unit. This system will be equipped with the Premium Amplifier package and will be addressable with the DRB. The amplifier as above is located under the passenger seat. The audio systems available in the JX are made up of the four corporate radios listed above with some additional options with regard to the amplification system. The list breaks down how the separate systems are made up. There are only two of the four radios that will be addressable on the CCD bus with the DRB. The key to knowing which system is addressable is the presence of an amplifier under the passenger seat. This amplifier utilizes a different instrument panel wiring harness that incorporates the CCD connector for the radio. Some of the radios may have a CCD connector in the radio chassis that may not have a connector plugged into it. This is entirely normal if there is no amplifier under the passenger seat. The RBS radio will be available with or without the premium amplifier and therefore will not be addressable via the CCD bus in some packages. When equipped with a Premium Amplifier package, there will be six speakers in the can The amplifier will drive the instrument panel speakers and the door speakers, while the radio will drive the speakers located in the rear quarter panels directly. This means that a "shorted channel" DTC can now be caused by a problem with the wiring or the resistance of the rear quarter panel speakers. In the past, the amplifier (if equipped) drove all the speakers and consequently the circuits from the amplifier to the speakers and the speakers themselves could not be the cause of a shorted channel DTC. 3.8.1 Diagnostics DIAGNOSTICS The RBS radio has several diagnostic messages that may be displayed in the event of a problem with either the radio or the CD changer option. These messages will be displayed on the radio faceplate in the following abbreviated form. The messages are as follows: Display Definition E L-SP LEFT CHANNEL SHORT Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2423 E R-SP RIGHT CHANNEL SHORT E EJCT CANNOT EJECT TAPE E LOAD CANNOT LOAD TAPE E PLAY CANNOT PLAY TAPE The following messages are for the CD changer options; E HOT THE CD CHANGER INTERNAL TEMPERATURE IS TOO HIGH E E-O1 CD CHANGER DEADLOCK (CD JAMMED, CAN'T LOAD OR EJECT) E E-06 CD CHANGER ELEVATOR ERROR E E-07 MAGAZINE EJECT ERROR E EEEE COMMUNICATIONS ERROR (BETWEEN RADIO AND CHANGER) E PLAY CANNOT READ ALL DISCS The left channel short, right channel short and communication error between the radio and CD changer are addressed in the diagnostics. Generally, the rest of the messages will require removal and repair of either the radio or the CD changer. NOTE: When using the diagnostic manual for troubleshooting radio systems, all voltages are D.C. unless otherwise specified. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The Vehicle Theft Security System (VTSS) module is a logic-controlled device (part of the body control module), that monitors vehicle doors, trunk key cylinder, and ignition action for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, courtesy and VTSS lamps, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the cluster will flash fast for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the trunk key cylinder switch is not seen by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. The indicator lamp blinks at a slow rate when the system is armed. For 1997 JX vehicles, once the VTSS is armed the universal garage door opener (if equipped) and the decklid release switch in the center console will be disabled. The decklid release will still operate from the RKE or using the key. When something triggers the alarm, the system will signal for about 18 minutes. For the first three minutes the horn will sound, then the headlamps and courtesy lamps will continue to flash for another 15 minutes. Tamper Alert - If the horn sounds three times when either front door is unlocked, it means the alarm was activated. Check the vehicle for tampering. The VTSS indicator lamp will also flash twice quickly to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by communication between the powertrain control module and the body control module. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2424 System Self-Tests - NOTE: System self-tests can be entered only with the DRB or MDS machine. Upon entering diagnostics, the headlamps, courtesy lamps and VTSS lamp will begin flashing to verify their operation. In addition, the horn will sound twice. Removing the key from the ignition switch will stop the lamps from flashing while keeping the system in diagnostics. While in diagnostics mode, a horn pulse should occur at each of the following events, which indicates proper operation. 1. Beginning with all doors closed, open, then close each door. The horn will sound when the door ajar switch closes, and then again when the switch opens. There must be a one-second delay between closing and opening the switch. 2. Rotate the key in each door lock cylinder to the unlock position. The horn will sound as the switch closes, and again when it opens. There must be a one-second delay between changing switch states, or the horn will not sound. 3. Cycle the key to the ignition RUN position. A single horn pulse will indicate proper operation of the ignition input. This also will take the module out of the diagnostics mode. For any of these tests, if the switch does not remain open or closed for at least one second, the horn will only sound once. The lack of a horn pulse during any operation indicates either: - a switch failure - the lack of that input to the vehicle theft security system module - a failure internal to the module - a faulty horn system Check for continuity at the switch. If this is good, check for an open or shorted wire between the switch and alarm module. Also, check if the Powertrain Control Module (PCM) has been replaced recently. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Vehicle Communication VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate 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 the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver 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 code determines the message that has higher priority, which is then allowed to access the bus first. The two wires 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. 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: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection for diagnostic and repair procedures. Any of the following bus failure messages may be displayed: Short to Battery Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground Either or both of the bus wires are shorted to ground or a specific ground may be open. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2425 Bus (+) & (-) Shorted Together The two bus wires are shorted together. No Termination The bus system has lost connection with all of its terminators. Bus Bias Level Too Low Either or both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High Either or both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias The bus system has lost connection with all modules that provide bias. Bus (+) Open The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open The bus (-) wire has lost connection with termination and/or bias. Not Receiving Bus Messages Correctly The DRB cannot communicate over the bus and does not know why. Wiper System WIPER SYSTEM The front wiper system provides the driver with normal wipe (low and high speeds), intermittent wipe, wiper after wash, and mist wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. Other wiper system features: Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled providing a range of from 1 second to 36 seconds. Mist Wipe When the wiper is in the off position and the driver presses the mist control for more than 125 msec, 1 wipe cycle in low speed mode will be provided. The wipe will continue in low speed as long as the switch is held in that position. Wiper After Wash Mode When the driver presses the wash button for over 3/8 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Body Control Module: Reading and Clearing Diagnostic Trouble Codes Displaying & Reading Trouble Codes CCD Data Link Connector Tip: Reading codes requires the use of a DRBII Diagnostic Readout Box or Equivalent Scan Tool. WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 10 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. NOTE: These diagnostic test procedures have been designed specifically for use with the Chrysler DRBII (Diagnostic Readout Box II). However it should be possible to perform the same tests using an equivalent Scan Tool. NOTE: It is not necessary to perform all of the tests in Diagnostic Charts to diagnose an individual code. Clearing Trouble Codes To clear codes, all codes must be "read," then proceed as follows: 1. After all codes have been read, press ATM. The display will change to the ERASE menu screen. 2. Press "1 ERASE CODES" to erase all codes. The display will return to the airbag menu screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2428 Body Control Module: Component Tests and General Diagnostics Diagnostic Notes - Read First 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. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active code(s). Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. 3.12.1 Active Codes ACTIVE CODES An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. 3.12.2 Stored Codes STORED CODES Airbag codes are automatically stored in the ACM's memory when the ignition is turned off with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2429 If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on," wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Manual A/C (HVAC) - Mode Door Operation MANUAL A/C (HVAC) MODE DOOR OPERATION The DRB trouble codes that indicate a stall failure or a feedback signal failure work together to show what is wrong with the HVAC system. The stall trouble codes mean that the Body Control Module (BCM) cannot force an actuator to the end of the mode door travel. Internal problems in the body control module will set other short-related trouble codes. Having only stall trouble codes indicates that there is a problem with an open or short circuit in the wiring, a bad actuator, a bad mode door or connecting linkage. It is important that the operation of the mode door be checked if an actuator is removed. This can be checked by rotating the door shaft to confirm that the door will stop at both ends of travel. The actuator itself has no stops. It must have the mode door to stop travel to pass the stall test. A feedback signal failure can occur on the mode door. The body control module monitors the feedback signal to check the position of the actuator. The body control module not only checks the level of the signal but also how much the voltage changes. A feedback failure can occur if there is a short or open circuit in the wiring, a bad actuator, a bad body control module, a bad mode door or connecting linkage. The easiest way to diagnose this is to use the DRB to actuate the mode door. Note that the feedback voltage of the actuator should smoothly change as the actuator is moved. A sudden change in the feedback voltage to a 5.0-volt or a 0.0-volt level indicates the actuator is bad. A fixed feedback voltage that is less than 5.0 volts or greater than 0.0 volts without a stall failure, or a short failure indicates that the actuator, the mode door, or a connecting mechanical linkage is jammed preventing movement. A feedback signal voltage that stays on 5.0 volts or 0.0 volts indicates a wiring or body control module problem. The feedback failure trouble code can also occur from a lack of actuator travel. This can be checked by confirming that the feedback signal smoothly changes when the actuator is moved with the DRB. If the signal is ok, the door travel is not correct. The actuator must be removed and the mode door mechanically checked for proper operation. Typical problems that prevent door movement include screws dropped in the A/C unit or warped doors. Replace any part that is found defective. Anytime the voltage to the BCM is interrupted for less than 2 minutes or voltage drops below approximately 10.0 volts (battery disconnected, etc.), it may be necessary to recalibrate the mode door. This can be done by using the DRB, MDS machine or removing the IOD (M1) fuse for 10 seconds, reinstall it and then start the engine. Diagnostic Strategies ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2430 Body Control Module: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRBIII DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform VEHICLE COMMUNICATION TEST 1A. DRBIII Error Messages DRBIII ERROR MESSAGE Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2431 Body Control Module: Service and Repair JUNCTION BLOCK REMOVAL Junction Block/BCM Location The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. Junction Block and Body Control Module assemblies are located on the driver's side of the vehicle. 1. Open the front driver's door and remove end cap. 2. Remove center bezel. 3. Remove instrument cluster hood. 4. Remove silencer. 5. Remove wire harness connectors from Junction Block. 6. Remove Junction Block three mounting screws. 7. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 8. Disconnect BCM wire connectors and remove the assembly. 9. Remove Junction Block/BCM from vehicle. INSTALLATION - For installation, reverse the above procedures. Ensure that the wire terminals and connectors are in good condition and connectors are properly installed. BODY CONTROL MODULE REMOVAL 1. The Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 2. Remove the two BCM attaching screws and release the two BCM locking latches from the Junction Block. 3. Disconnect BCM from the Junction Block. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2432 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII (diagnostic read-out box) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2436 Brake Signal: Description and Operation When the brake switch is activated, the PCM receives an input indicating that brakes are being applied. The brake switch is mounted on the brake pedal support bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) Camshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2440 Camshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2441 Camshaft Position Sensor: Description and Operation Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. OPERATION This vehicle is equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. The distributor is also equipped with an internal camshaft position (fuel sync) sensor Fig. 2. This sensor provides fuel injection synchronization and cylinder identification to the PCM. The camshaft position sensor contains a hall effect device called a sync signal generator. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the shutter enters the sync signal generator, the interruption of magnetic field causes the voltage to switch high. This causes a sync signal of approximately 5 volts. When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts. Since the shutter rotates at half crankshaft speed, it may take one engine revolution during cranking for the PCM to determine the position of piston number 6. NO CAM SIGNAL AT PCM FAULT MESSAGE Purpose The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. Operation The sensor is provided with 12 volts from the fused ignition switch output circuit and the powertrain control module supplies a sensor ground. The CMP sensor has a 5 volt pull-up from the PCM. The sensor signal is created when the distributor's pulse ring is rotated past the camshaft position sensor. When Monitored: The crankshaft position sensor signal trouble code is not set. With the ignition in either the start or run position and battery voltage between 4 and 15 volts. Set Condition: Too many crankshaft position sensor signals detected without any camshaft position sensor signal Possible Causes: Open fused ignition switch output circuit (12V) - Open sensor ground - Damaged pulse ring - Failed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2442 - Failed PCM - Inoperative distributor drive - Broken timing belt - Connector terminals - Connector wires Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 2445 Camshaft Position Sensor: Service and Repair The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant temperature sensor torque ..................................................................................................... .......................................................... 27 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2449 Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor And Oil Pressure Switch Locations Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2450 Engine Coolant Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2451 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor is installed in the housing between the filler neck and thermostat Fig. 7. The sensor provides an input voltage to the PCM. The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emissions and improve driveability - Because spark advance changes at different engine operating temperatures during warm-up, all spark advance testing should be done with the engine fully warmed. The PCM demands slightly richer air-fuel mixtures and higher idle speeds until the engine reaches normal operating temperature. The engine coolant sensor input is also used for radiator fan control. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. This sensor input is also used for the instrument cluster coolant temperature gauge. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 4 Engine Coolant Temperature Sensor 1. With key off, disconnect wire connector from engine coolant temperature sensor Fig. 4. 2. Connect one lead of ohmmeter to one terminal of engine coolant temperature sensor. 3. Connect the other lead of ohmmeter to remaining terminal of engine coolant temperature sensor. The ohmmeter should read as follows; - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F, ohmmeter should read approximately 7,000 to 13,000 ohms. 4. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between connector terminal 43 and the sensor harness connector. Refer to Wiring Diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2454 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2455 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. REMOVAL 1. Drain cooling system until coolant level is below engine coolant temperature sensor. Refer to Cooling System. 2. Disconnect electrical connector from sensor. 3. Remove sensor from engine. INSTALLATION 1. Install ECT sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor screw torque ................................................................................................................................................... 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2459 Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2460 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2461 Crankshaft Position Sensor: Description and Operation Fig. 5 Timing Slots Fig. 3 Crankshaft Position Sensor--Adjustable Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2462 Fig 12 Crankshaft Position Sensor Location -- Typical OPERATION The crankshaft position sensor Fig. 3 detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots Fig. 5. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. - The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. - It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The sensor connector has a Christmas tree attached to the heater tube bracket. - The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On automatic transmission vehicles this circuit is spliced and provides an input to the Transmission Control Module (TCM). The PCM provides a ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. HELPFUL INFORMATION The K7 circuit supplies 8 volts to the distributor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 9 Crankshaft Position Sensor REMOVAL 1. Remove speed control servo from driver's side strut tower. 2. Remove crankshaft position sensor retaining bolt Fig. 9. 3. Pull crankshaft position sensor straight up out of the transaxle housing. 4. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. INSTALLATION - ADJUSTABLE Some vehicles may be equipped with an adjustable crankshaft position sensor. This can be identified by an elongated mounting hole in the sensor. Fig. 10 Crankshaft Position Sensor And Spacer If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor Fig. 10. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 2. Connect crankshaft position sensor electrical connector to the wiring harness connector. 3. Attach connector to heater tube bracket. 4. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. INSTALLATION - NON-ADJUSTABLE 1. Install sensor in transaxle. 2. Install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. 4. Attach connector to heater tube bracket. 5. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2467 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Fig. 2 Data Link (Diagnostic) Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2473 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2474 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2475 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2484 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2486 Data Link Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2487 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 Data Link Connector: Connector Views Data Link Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2490 Data Link Connector: Description and Operation CIRCUIT OPERATION Circuit M1 supplies battery voltage to the universal data link connector. This circuit is protected by a 10 Amp fuse located in cavity 5 of the junction block. Circuit M1 is the Ignition-Off Draw circuit and supplies power to the Body Control Module (BCM), radio memory, interior lamps, and other components. A twisted pair of wires, circuits D1 and D2, connect to the data link connector. These wires are connected to the CCD Bus. The CCD Bus is used for diagnosing vehicle components and modules. Circuits D20 and D21 from the Powertrain Control Module (PCM) connect to the data link connector. Circuit D20 connects to cavity 75 of the PCM and is the SCI receive circuit. Circuit D21 connects to cavity 65 of the PCM and is the SCI transmit. The D21 circuit is also spliced and connects to the Transmission Control Module (TCM), and the Controller Anti Lock Brakes (CAB), if equipped. The D6 circuit is also connected to the universal data link connector. This circuit is used as a SCI line from the TCM. The universal data link connector is also interfaced with the CCD Bus. Circuit D1 is used for CCD (+) and D2 is used for CCD (-). There are also two grounds used for the universal data link connector. One is a power ground and one is a regular ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations Fig. 29 EGR Control Valve Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations > Page 2494 EGR Backpressure Transducer: Description and Operation Fig. 27 Electronic EGR Transducer Fig. 29 EGR Control Valve The Electric EGR Transducer contains an electrically operated solenoid and a back-pressure controlled vacuum transducer Fig. 27. The PCM operates the solenoid based on inputs from the multi-port fuel injection system. The solenoid/transducer and EGR valve are serviced as an assembly. When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to the transducer when the PCM de-energizes the solenoid. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the vacuum transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of the vacuum signal applied to the EGR valve. Varying the strength of the vacuum signal changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. The solenoid/transducer and EGR valve mount to the rear of the cylinder head Fig. 28 or 29. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations > Page 2495 EGR Backpressure Transducer: Testing and Inspection The first part of this test will determine if the transducer diaphragm at the back-pressure has ruptured or is leaking. The second part of the test will determine if engine vacuum (full manifold) is flowing from the inlet to the outlet side of the transducer. 1. Electrical operation of the solenoid should be checked with the DRB scan tool before proceeding with the vacuum test. 2. Disconnect the rubber back-pressure hose from the fitting at the bottom of the transducer. 3. Connect a hand-held vacuum pump to this fitting. 4. Apply 10 inches of vacuum to this fitting. 5. If vacuum falls off, the transducer diaphragm is leaking. 6. Replace the transducer and EGR valve assembly. Connect the rubber hose to the transducer and proceed to next step for further testing. 7. Remove the rubber hose at the vacuum inlet fitting on the EGR solenoid. 8. Connect a vacuum gauge to this disconnected hose. 9. Start the engine and bring to operating temperature. Hold engine speed at approximately 1,500 rpm. 10. Check for steady engine vacuum (full manifold) at this hose. If engine vacuum is not present, check vacuum line to engine and repair as necessary before proceeding to next step. 11. Connect the hose to the vacuum inlet fitting on the solenoid. 12. Disconnect the rubber hose at the vacuum outlet hose on the transducer. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical connector from the solenoid. This will simulate an open circuit. 15. Start the engine and bring to operating temperature. - Hold the engine speed at approximately 2,000 rpm while checking for vacuum (full manifold) at this fitting. - As temporary back-pressure is built, full manifold vacuum should be observed at the outlet fitting. - Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low. This low reading is normal. - At idle speed, the gauge reading will be erratic. This is also normal. 16. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the transducer and EGR valve assembly. Refer to EGR Valve Replacement. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Service and Repair > EGR Valve and Electric EGR Transducer Replacement EGR Backpressure Transducer: Service and Repair EGR Valve and Electric EGR Transducer Replacement Fig. 2 EGR Control Valve Fig. 3 EGR Valve NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and electrical transducer are calibrated together. NOTE: The EGR valve attaches to the front exhaust manifold. The transducer/solenoid attach to the front cylinder head (Fig. 3). REMOVAL 1. Disconnect vacuum supply and outlet hose from solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove back-pressure hose from transducer. 4. Pull transducer/solenoid up off of bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Service and Repair > EGR Valve and Electric EGR Transducer Replacement > Page 2498 Fig. 5 TCM Removal Fig. 6 EGR Removal; 5. Remove screws holding Transmission Control Module (TCM) to bracket (Fig. 5). Swing TCM up to allow access to EGR screws (Fig. 6). 6. Remove screws holding EGR tube. 7. Remove EGR valve mounting screws. Remove EGR valve and transducer. 8. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lbs) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lbs) torque. 5. Clip solenoid to bracket. 6. Connect back-pressure hose to EGR valve and transducer. 7. Connect vacuum supply and outlet hoses to solenoid. 8. Attach electrical connector to solenoid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Service and Repair > EGR Valve and Electric EGR Transducer Replacement > Page 2499 EGR Backpressure Transducer: Service and Repair EGR Tube Fig. 8 EGR Tube At Intake Manifold NOTE: The EGR tube attaches to the intake manifold plenum behind the throttle body and to the EGR valve. REMOVAL 1. Remove screws attaching EGR tube to intake manifold (Fig. 8). Fig. 9 EGR Tube At EGR Valve 2. Remove EGR tube to EGR valve screws (Fig. 9). 3. Remove EGR tube. Clean gasket surface on the EGR valve. Wipe clean the grommet on the intake manifold. NOTE: Use new gaskets on both ends of the EGR tube. INSTALLATION 1. Loosely install the EGR tube and fasteners. 2. Tighten the EGR tube to intake manifold plenum screws to 11 Nm (95 in lb) torque. 3. Tighten the EGR tube to EGR valve screws to 11 Nm (95 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications Powertrain Control Module: Specifications PCM Mounting screw torque ............................................................................................................... .......................................................... 4 Nm (35 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module: Component Locations Fig. 16 Power Distribution Center (PDC) The Powertrain Control Module (PCM) is located in the left front engine compartment close to the transmission control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2505 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2522 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2523 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2524 Powertrain Control Module: Connector Views Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2525 PCM Connector View Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2526 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. 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 because of corrosion. - 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. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description Powertrain Control Module: Description and Operation Component Description Fig.9 Power Distribution Center (PDC) The PCM regulates the ignition system. The PCM supplies battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM controls ignition timing by turning on and off a transistor in the distributor. During the crank-start period the PCM maintains spark advance at 9° BTDC. During engine operation the following inputs determine the amount of spark advance provided by the PCM. Intake air temperature. - Coolant temperature. - Engine RPM. - Intake manifold vacuum. The PCM also regulates the fuel injection system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description > Page 2529 Powertrain Control Module: Description and Operation PCM Battery Feed CIRCUIT OPERATION Circuit A14 is used to provide a constant battery feed to the Powertrain Control Module (PCM). This circuit originates in the Power Distribution Center (PDC) and is protected by a 20 Amp fuse located in cavity 5. It is also spliced and provides power for the Automatic Shut Down (ASD) relay, coil and contact sides. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description > Page 2530 Powertrain Control Module: Description and Operation Power (Device) Ground Helpful Information Circuit Z12 which supplies a ground for the PCM high current drivers, terminates at the left strut tower. If the system loses ground for the Z12 circuit the vehicle will not operate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description > Page 2531 Powertrain Control Module: Description and Operation System Operation SYSTEM OPERATION Powertrain Control Module The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. See Charging System/Testing and Inspection/Procedures/On-board Diagnostic System Test. The PCM cannot be repaired and must be replaced if faulty. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Powertrain Control Module: Component Tests and General Diagnostics Component Testing Testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Diagnostic Charts For Trouble Code charts see Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts. See: Testing and Inspection SBEC Testing No specific procedures are provided to diagnose the SBEC by itself. Please See: Computers and Control Systems, Testing and Inspection. SBEC failure is determined as a result of a related system failure. See: Testing and Inspection Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2534 Powertrain Control Module: Service and Repair Fig. 33 Auxiliary Jumper Terminal POWERTRAIN CONTROL MODULE SERVICE The PCM attaches to a bracket between the air cleaner housing and Power Distribution Center (PDC) Fig. 33. REMOVAL 1. Disconnect negative cable from auxiliary jumper terminal Fig. 33. 2. Disconnect both 40-way connectors from PCM. Fig. 34 PCM Bracket Screws 3. Remove screws attaching PCM to bracket Fig. 34. 4. Lift PCM up to remove it from vehicle. INSTALLATION 1. Install PCM. Tighten mounting screws. 2. Attach both 40-way connectors to PCM. 3. Connect negative cable to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel level input comes across the CCD bus from the body control module. this input is used for the Fuel System and Misfire Monitors. If the fuel level is below approximately 1/16th of a tank the Fuel System and Misfire monitors will be disabled. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control Motor screws .............................................................................................................. ......................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2541 Idle Speed/Throttle Actuator - Electronic: Locations Idle Air Control Motor Fig. 32 Idle Air Control Motor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2542 Idle Air Control Motor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2543 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig. 32 Idle Air Control Motor PURPOSE The Idle Air Control (IAC) motor is mounted on the throttle body. The PCM operates the idle air control motor Fig. 31. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load, coolant temperature or barometric pressure changes. OPERATION The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC motor pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning and power steering). CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the idle air control motor through 4 circuits - K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector Circuit K39 connects to cavity 57 of the PCM connector - Circuit K40 connects to cavity 48 of the PCM connector - Circuit K59 connects to cavity 58 of the PCM connector - Circuit K60 connects to cavity 49 of the PCM connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2544 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 26 Throttle Position Sensor And Idle Air Control Motor The idle air control motor attaches to the side of the throttle body Fig. 26. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Remove throttle body. 3. Disconnect electrical connector from idle air control motor and throttle position sensor. 4. Remove idle air control motor mounting screws. 5. Remove idle air control motor. Ensure 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB AIS Motor Open/Close Test to retract the pintle (battery must be connected.) 2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install throttle body. 5. Attach electrical connectors to idle air control motor and throttle position sensor. 6. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 Information Bus: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Chrysler Collision Detection Multiplex System (CCD Bus) Information Bus: Description and Operation Chrysler Collision Detection Multiplex System (CCD Bus) OPERATION Various modules exchange information through a communications port called the CCD bus. The PCM transmits the Malfunction Indicator (Check Engine) Lamp On/Off signal and engine rpm on the CCD Bus. The PCM receives the air conditioning select input, transaxle gear position input and speed control engage inputs over the CCD Bus. The PCM also receives the air conditioning evaporator temperature signal from the CCD Bus. The following components access or send information on the CCD Bus: Instrument panel - Body Control Module - Air Bag System Diagnostic Module - Full ATC Display Head - ABS Module - Transmission Control Module - Powertrain Control Module - Overhead Travel Module CIRCUIT OPERATION The CCD Bus is used to allow the Powertrain Control Module (PCM) and other modules to communicate with each other and the universal data link connector. Circuit D1 is used for CCD (+) and connects to cavity 59 of the PCM connector. Circuit D2 is used for CCD (-) and connects to cavity 60 of the PCM connector. The CCD Bus is used to supply all of the communications between the Body Control Module (BCM) and the instrument cluster. The bus wires are a twisted pair. There are two different circuits used for the bus. The positive side of the bus wire is accomplished on the D1 circuit, and the negative is on the D2 circuit. The CCD Bus and the universal data link connector are used for access to the diagnostic capabilities of the radio. Circuits D1 and D2 are used. The D1 circuit is used for CCD (+) and circuit D2 is used for CCD (-). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Chrysler Collision Detection Multiplex System (CCD Bus) > Page 2568 Information Bus: Description and Operation Circuit Operation CIRCUIT OPERATION The CCD Bus is used to supply all of the communications between the Body Control Module (BCM) and the instrument cluster. The bus wires are a twisted pair. There are two different circuits used for the bus. The positive side of the bus wire is accomplished on the D1 circuit, and the negative is on the D2 circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 - Check for a blown 20 Amp fuse in cavity 8 of the junction block - Check the 20 Amp fuse located in cavity 8 of the PDC - Check the case ground attached to the rear of the radio - Check the 10 Amp IOD fuse located in cavity 5 of the junction block Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2574 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2575 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2576 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2577 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2578 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, generator field, electronic ignition coil and the heating elements in the oxygen sensors. Refer to Diagrams/Electrical for circuit information. The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. OPERATION The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. When the ignition switch is in On or Start, the PCM momentarily turns on the ASD relay. The PCM also monitors the ASD relay output voltage. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. While the relay is on the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the PDC Fig. 25. The inside top of the PDC cover has label showing relay and fuse identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2579 Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Power for the coil and contact side of the relay is provided by circuit A14. This circuit is HOT at all times and protected by a 20 amp fuse located in cavity 5 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the relay on circuit K51. This circuit connects to cavity 67 of the PCM connector. When the relay is energized, the contacts internal to the relay close connecting circuits A14 and A142. The A142 circuit is spliced and provides power to the fuel injectors, generator, electronic EGR transducer solenoid, and the ignition coil. The A142 circuit is also spliced and connects to the PCM connector, cavity 6. This input is used for ASD sense by the PCM. HELPFUL INFORMATION Check the 20 amp fuse located in cavity 5 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in cavity 5 of the PDC Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2582 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD Relay Test Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2583 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 1 ASD And Fuel Pump Relay Terminals OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Electrical Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CIRCUIT OPERATION The check engine lamp is used to indicate to the operator a problem in the engine control system. If a problem is detected, the Powertrain Control Module (PCM) sends a message, over the CCD Bus, to the Body Control Module (BCM). The BCM interprets this message and sends a signal to the instrument cluster to illuminate the lamp. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. The bulb check operation is controlled by the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2591 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP sensor torque .............................................................................................................................. ....................................................... 3.4 Nm (30 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2592 Fig. 21 Intake Air Temperature Sensor And MAP Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2593 Map Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2594 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 5 Intake Air Temperature Sensor And MAP Sensor OPERATION The MAP sensor reacts to absolute pressure in the intake manifold and provides an input voltage to the PCM. The PCM interprets the MAP sensor input as engine load. The input voltage level supplies the PCM with information relating to ambient barometric pressure during engine start-up (cranking) and engine load while its operating. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. The PCM supplies 5 volts direct current to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. At key on, before the engine is started, the PCM determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The sensor is mounted on the intake manifold Fig. 1. The sensor is connected to the throttle body or intake manifold with a vacuum hose and to the PCM electrically CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Manifold Absolute Pressure (MAP) sensor Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides a ground path for the MAP signal (circuit K1) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 30 MAP Sensor Connector NOTE: Complete testing of this component and its circuit is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 3 (Fig. 30). - With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. - The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. - If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (+/0.5V). Five volts (+/-0.5V) should also be at terminal 43 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. NOTE: Complete testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2597 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 volts to the A/C pressure switch and the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Throttle position sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2598 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 21 Intake Air Temperature Sensor And MAP Sensor The MAP sensor attaches to the intake manifold plenum Fig. 21. REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seal. 2. Tighten mounting screws to 3.4 Nm (30 in. lbs.) torque. 3. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle Technical Service Bulletin # 18-01-98 Date: 980116 MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle NO: 18-01-98 GROUP: Driveability DATE: Jan. 16, 1998 SUBJECT: MIL Illumination with Hex Code $3E, Possible Sags/Hesitations/Rough Idle MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: MIL illumination with hex code $3E - UPSTREAM O2 SENSOR SHORTED TO VOLTAGE along with possible symptoms of sags/hesitation or rough idle. NOTE: HEX CODE $3E MUST BE SEEN TO PERFORM THIS REPAIR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-94-TF-91 0.4 Hrs. FAILURE CODE: P8 - New Part 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 DTC $3E is present, follow the diagnostic procedure in the applicable diagnostic manual. If no apparent reason is found for the DTC, perform the Repair Procedure. Parts/Equipment Required 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable AR (1) 05010885AA Kit, Oxygen Sensor Jumper (4-cyl & 96/97 6-cyl) AR (1) 05010934AA Kit, Oxygen Sensor Jumper (1995 6-cyl) AR 04778570 Heat Shrink Tubing AR (1) 04778138 Tape, Cloth Underhood Electrical 1 NPN Soldering Iron 1 NPN Rosin Core Solder Repair Procedures This bulletin involves cutting and splicing a jumper from the oxygen sensor(s) to the powertrain control module. Single Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector and disconnect it. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2607 3. Identify the sensor ground terminal. For 1997 models it is terminal No. 3, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). For 1995/1996 models it is terminal No. 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1997 connectors use a rear secondary lock latch at the rear side of the connector. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 3 by carefully pulling from the rear while spreading the two locking fingers. 1995/1996 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal No. 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out from the rear. 5. Choose the terminal on the end of the repair lead p/n 05010885AA that matches the removed terminal. Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. NOTE: THE TERMINAL END ON THE OPPOSITE END OF THE NEW LEAD IS FOR THE OTHER APPLICABLE YEAR VEHICLES. THIS TERMINAL MUST BE CLIPPED OFF. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2608 8. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 9. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 10. Cut the k4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 11. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. 12. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 13. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 14. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 15. Reconnect the battery negative cable. 16. Verify the wiring repair by running the oxygen sensor test with the DRB III. Double Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector # 1 and disconnect it. 3. Identify the sensor ground terminal. For 1995 models, it is terminal # 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1995 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal # 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out form the rear. 5. Choose the terminal on the end of the repair lead p/n 05010934AA that has the longer length of wire from the Y splice (1100 mm). Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Repeat steps 3 through 6 for the upstream oxygen sensor No. 2, using the other lead from the Y spliced repair jumper. 8. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. 9. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 10. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 11. Cut the K4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2609 13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 14. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 15. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 16. Reconnect the battery negative cable. 17. Verify the wiring repair by running the oxygen sensor test with the DRB III. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle Technical Service Bulletin # 18-01-98 Date: 980116 MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle NO: 18-01-98 GROUP: Driveability DATE: Jan. 16, 1998 SUBJECT: MIL Illumination with Hex Code $3E, Possible Sags/Hesitations/Rough Idle MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: MIL illumination with hex code $3E - UPSTREAM O2 SENSOR SHORTED TO VOLTAGE along with possible symptoms of sags/hesitation or rough idle. NOTE: HEX CODE $3E MUST BE SEEN TO PERFORM THIS REPAIR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-94-TF-91 0.4 Hrs. FAILURE CODE: P8 - New Part 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 DTC $3E is present, follow the diagnostic procedure in the applicable diagnostic manual. If no apparent reason is found for the DTC, perform the Repair Procedure. Parts/Equipment Required 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable AR (1) 05010885AA Kit, Oxygen Sensor Jumper (4-cyl & 96/97 6-cyl) AR (1) 05010934AA Kit, Oxygen Sensor Jumper (1995 6-cyl) AR 04778570 Heat Shrink Tubing AR (1) 04778138 Tape, Cloth Underhood Electrical 1 NPN Soldering Iron 1 NPN Rosin Core Solder Repair Procedures This bulletin involves cutting and splicing a jumper from the oxygen sensor(s) to the powertrain control module. Single Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector and disconnect it. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2615 3. Identify the sensor ground terminal. For 1997 models it is terminal No. 3, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). For 1995/1996 models it is terminal No. 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1997 connectors use a rear secondary lock latch at the rear side of the connector. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 3 by carefully pulling from the rear while spreading the two locking fingers. 1995/1996 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal No. 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out from the rear. 5. Choose the terminal on the end of the repair lead p/n 05010885AA that matches the removed terminal. Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. NOTE: THE TERMINAL END ON THE OPPOSITE END OF THE NEW LEAD IS FOR THE OTHER APPLICABLE YEAR VEHICLES. THIS TERMINAL MUST BE CLIPPED OFF. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2616 8. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 9. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 10. Cut the k4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 11. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. 12. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 13. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 14. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 15. Reconnect the battery negative cable. 16. Verify the wiring repair by running the oxygen sensor test with the DRB III. Double Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector # 1 and disconnect it. 3. Identify the sensor ground terminal. For 1995 models, it is terminal # 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1995 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal # 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out form the rear. 5. Choose the terminal on the end of the repair lead p/n 05010934AA that has the longer length of wire from the Y splice (1100 mm). Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Repeat steps 3 through 6 for the upstream oxygen sensor No. 2, using the other lead from the Y spliced repair jumper. 8. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. 9. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 10. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 11. Cut the K4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2617 13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 14. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 15. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 16. Reconnect the battery negative cable. 17. Verify the wiring repair by running the oxygen sensor test with the DRB III. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2618 Oxygen Sensor: Specifications - After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. - If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite (R) 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. - Tighten the sensor to 28 Nm (20 ft. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2621 Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2622 Fig 12 Upstream Heated Oxygen Sensor 1/1 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Front Upstream Oxygen Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor > Page 2625 Downstream Oxygen Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2626 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2627 Oxygen Sensor: Description and Operation Fig 12 Upstream Heated Oxygen Sensor 1/1 OPERATION As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic converter, one downstream of the converter. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop. the PCM adjusts injector pulse width based on preprogrammed (fixed values and inputs from other sensors. The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 12). Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2628 DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 13). The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. CIRCUIT OPERATION Circuit A14 is connected to the BUS bar in the Power Distribution Center (PDC), which connects to battery voltage. The contact side of the Automatic Shut-Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse, located in cavity 5 of the PDC, protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM. The A142 circuit also splices to cavity 6 of the PCM connector. The input by circuit A142 tells the PCM that the ASD relay is energized. The A142 circuit supplies voltage for the upstream heated oxygen sensor and circuit F142 supplies voltage to the downstream heated oxygen sensor. The F142 circuit is protected by a 10 Amp fuse located in cavity 1 of the PDC. Power for the fuse is supplied by circuit A142. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the downstream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream (left) and downstream (right) heated oxygen sensor signals (circuits K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Circuit Z1 provides the ground path for the heater circuits in the sensors. This ground terminates at the right frame rail. Circuit K4 splices to supply ground for the signals for the following: Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Vehicle speed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, distributor, ASD relay, generator, and the EGR solenoid. The PCM controls the ground path for each of the components powered by circuit A142. Circuit K4 splices to supply ground for the signals for the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Vehicle speed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2631 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 5 and 7 ohms. NOTE: This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. NOTE: Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS ONLY (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 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 connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See, sensor heating element test. 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. NOTE: Complete testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 2632 Oxygen Sensor: Service and Repair Fig 89 Upstream Oxygen Sensor REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector from sensor. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 89). INSTALLATION 1. After removing the sensor the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. - If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. - Tighten the sensor to 28 Nm (20 ft lb) torque. 2. Connect electrical connector to sensor. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 2633 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revision NUMBER: 26-10-96 GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus, Stratus & Breeze - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs 8W-80-44 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2638 8W-80-45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2639 8W-80-46 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2640 8W-80-47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2643 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2644 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2645 Power Steering Pressure Switch: Description and Operation Fig. 21 Power Steering Pressure Switch PURPOSE On some vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. OPERATION The pressure switch improves vehicle idle quality, by maintaining required engine idle speed when necessary, do to increased pressure in the power steering system. This increased pressure will slow down the power steering pump which will decrease engine idle speed. The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear on vehicle's requiring its usage. When power steering pump pressure exceeds 4137 kPa (600 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z1 provides a ground for the power steering pressure switch. The ground is terminated at the left strut tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2646 Power Steering Pressure Switch: Service and Repair REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on the back side of the power steering gear. 4. Remove the vehicle's wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations ETACS-ECU ETACS-ECU Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 Body Control Module: Connector Views Body 20 Way Connector (At BCM) Engine 14 Way Connector (At BCM) Instrument Panel 10-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 Instrument Panel 22-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 Body Control Module: Electrical Diagrams Body Control Module Wiring Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information Technician Safety Information WARNING: Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. 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. SERVICING SUB-ASSEMBLIES 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. Only those components with approved Service and Repair procedures in this database should be serviced. DRBIII Scantool Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRB if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. - Do not exceed the limits shown in the table above. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2684 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". 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 because of corrosion. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms Body Control Module: Application and ID Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The terms "gage" and "gauge" are used interchangeably Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms > Page 2687 Body Control Module: Application and ID Body Codes Defined JA ............................................................................................................................................................ Chrysler Cirrus, Plymouth Breeze, Dodge Stratus JX ......................................................................... ................................................................................................................... Chrysler Sebring Convertible Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Active Codes: A malfunction that is present now. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2690 ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2691 Body Control Module: Description and Operation Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2692 Body Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2693 Body Control Module: Description and Operation Climate Control Systems A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2694 Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2695 Active Codes: A malfunction that is present now. ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2696 protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Compass Mini-Trip Computer (CMTC) COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located on the right hand side of the instrument cluster. The CMTC is an electronic control module with a Vacuum Fluorescent Display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. Upon ignition the CMTC will turn on all of the segments in the display for 1 second then reverts to the last function screen that was displayed prior to the last ignition cycle. The functions that are available via actuation of the STEP switch are as follows: - Compass and Ambient Temperature - Average Trip Fuel Economy (AVE ECO) - Estimated Range (RANGE) - Present Fuel Economy (ECO) - Trip Odometer (ODO) - Elapsed Ignition On Time (ET) - Blank Screen (off) Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2697 NOTE: The terms "gage" and "gauge" are used interchangeably Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of four gauges, the status of seven indicator lamps, the status and dimming of the PRNDL indicator (VF display), and the dimming of cruise and low fuel lamps to the Mechanical Instrument Cluster (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run," or "start" positions. The PRNDL indicator works when the ignition is in the "off," "run," or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all PRNDL segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the tachometer exceeds 450 rpm. Power Door Lock System POWER DOOR LOCK SYSTEM When the Body Control Module (BCM) receives an input for a lock/unlock request (door lock switch, Remote Keyless Entry (RKE), or door key cylinder switch (w/VTSS only), it will ground the appropriate relay for a specified amount of time. For this vehicle all door lock relays are located inside the body control module and are not serviced separately. The door lock switches provide a variable voltage (Multiplexed (MUX) circuit) to the BCM and the BCM will respond to that command. If the conditions for door lock inhibit exist (key in ignition and left front door open), the BCM will not respond to a lock command. Other power door lock features: Automatic Door Locks This feature can be enabled/disabled by using either the DRB, MDS machine or customer key cycle method. When enabled, all the doors will lock when the vehicle reaches a speed greater than 15 MPH, all doors are closed and an increase of TPS signal is received by the PCM. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the vehicle speed accelerates above 15 MPH. Remote Keyless Entry (RKE) The body control module receives and decodes messages from the remote keyless entry transmitter. The remote keyless entry module is built into the BCM (premium) and is not serviced separately. When the lock button is pressed all doors will lock, horn will chirp, courtesy lamps will turn off and VTSS (if equipped) will arm. When the unlock button is pressed once, the left front door will unlock, courtesy lamps will light (if equipped w/illuminated entry) and VTSS (if equipped) will disarm. If the unlock button is pressed a second time (within 5 seconds of the first), all the other doors will unlock. Panic mode (if equipped with VTSS), is accomplished by pressing both lock and unlock buttons at the same time. 1997 JX transmitters have a separate panic button. This flashes the lights and sounds the horn but does not prevent the engine from running. The BCM will ignore all commands from the transmitter if the vehicle speed is over 15 MPH. This allows the engine to be running during warm up on cold days and then using the RKE to unlock the doors. The RKE software can store up to 4 transmitter codes. Rolling Code (97 JX only) The rolling code features changes part of the key fob (transmitter) message each time it is used. The key fob message and the receiver message increment together. Under certain conditions with a rolling code system (like pressing a button on the fob over 250 times outside of the receiver range) the receiver and transmitter can fall out of synchronization. By pressing specific buttons together, the system will re-synchronize. Radio-CCD RADIO - CCD NOTE: At the present time all 1997 CCD radios are not connected to the CCD bus. The audio systems used in the JX convertible will consist of one of the following radios: RAL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2698 RAL - Base radio with AM/FM stereo, bass and treble sliders only. RBS RBS - AM/FM stereo with cassette tape and CD changer option. Bass and treble controls. This radio may or may not be addressable with DRB. If it is equipped with the Premium Amplifier option (located under the passenger seat), it will be on the CCD bus. The Amplifier will determine whether the CCD connector in the back of the radio is wired. RBR RBR - AM/FM stereo with CD player only. Three band E.Q. Not connected to the bus. Not addressable with DRB. RAZ RAZ - AM/FM stereo with cassette and CD player incorporated into one unit. This system will be equipped with the Premium Amplifier package and will be addressable with the DRB. The amplifier as above is located under the passenger seat. The audio systems available in the JX are made up of the four corporate radios listed above with some additional options with regard to the amplification system. The list breaks down how the separate systems are made up. There are only two of the four radios that will be addressable on the CCD bus with the DRB. The key to knowing which system is addressable is the presence of an amplifier under the passenger seat. This amplifier utilizes a different instrument panel wiring harness that incorporates the CCD connector for the radio. Some of the radios may have a CCD connector in the radio chassis that may not have a connector plugged into it. This is entirely normal if there is no amplifier under the passenger seat. The RBS radio will be available with or without the premium amplifier and therefore will not be addressable via the CCD bus in some packages. When equipped with a Premium Amplifier package, there will be six speakers in the can The amplifier will drive the instrument panel speakers and the door speakers, while the radio will drive the speakers located in the rear quarter panels directly. This means that a "shorted channel" DTC can now be caused by a problem with the wiring or the resistance of the rear quarter panel speakers. In the past, the amplifier (if equipped) drove all the speakers and consequently the circuits from the amplifier to the speakers and the speakers themselves could not be the cause of a shorted channel DTC. 3.8.1 Diagnostics DIAGNOSTICS The RBS radio has several diagnostic messages that may be displayed in the event of a problem with either the radio or the CD changer option. These messages will be displayed on the radio faceplate in the following abbreviated form. The messages are as follows: Display Definition E L-SP LEFT CHANNEL SHORT Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2699 E R-SP RIGHT CHANNEL SHORT E EJCT CANNOT EJECT TAPE E LOAD CANNOT LOAD TAPE E PLAY CANNOT PLAY TAPE The following messages are for the CD changer options; E HOT THE CD CHANGER INTERNAL TEMPERATURE IS TOO HIGH E E-O1 CD CHANGER DEADLOCK (CD JAMMED, CAN'T LOAD OR EJECT) E E-06 CD CHANGER ELEVATOR ERROR E E-07 MAGAZINE EJECT ERROR E EEEE COMMUNICATIONS ERROR (BETWEEN RADIO AND CHANGER) E PLAY CANNOT READ ALL DISCS The left channel short, right channel short and communication error between the radio and CD changer are addressed in the diagnostics. Generally, the rest of the messages will require removal and repair of either the radio or the CD changer. NOTE: When using the diagnostic manual for troubleshooting radio systems, all voltages are D.C. unless otherwise specified. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The Vehicle Theft Security System (VTSS) module is a logic-controlled device (part of the body control module), that monitors vehicle doors, trunk key cylinder, and ignition action for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, courtesy and VTSS lamps, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the cluster will flash fast for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the trunk key cylinder switch is not seen by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. The indicator lamp blinks at a slow rate when the system is armed. For 1997 JX vehicles, once the VTSS is armed the universal garage door opener (if equipped) and the decklid release switch in the center console will be disabled. The decklid release will still operate from the RKE or using the key. When something triggers the alarm, the system will signal for about 18 minutes. For the first three minutes the horn will sound, then the headlamps and courtesy lamps will continue to flash for another 15 minutes. Tamper Alert - If the horn sounds three times when either front door is unlocked, it means the alarm was activated. Check the vehicle for tampering. The VTSS indicator lamp will also flash twice quickly to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by communication between the powertrain control module and the body control module. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2700 System Self-Tests - NOTE: System self-tests can be entered only with the DRB or MDS machine. Upon entering diagnostics, the headlamps, courtesy lamps and VTSS lamp will begin flashing to verify their operation. In addition, the horn will sound twice. Removing the key from the ignition switch will stop the lamps from flashing while keeping the system in diagnostics. While in diagnostics mode, a horn pulse should occur at each of the following events, which indicates proper operation. 1. Beginning with all doors closed, open, then close each door. The horn will sound when the door ajar switch closes, and then again when the switch opens. There must be a one-second delay between closing and opening the switch. 2. Rotate the key in each door lock cylinder to the unlock position. The horn will sound as the switch closes, and again when it opens. There must be a one-second delay between changing switch states, or the horn will not sound. 3. Cycle the key to the ignition RUN position. A single horn pulse will indicate proper operation of the ignition input. This also will take the module out of the diagnostics mode. For any of these tests, if the switch does not remain open or closed for at least one second, the horn will only sound once. The lack of a horn pulse during any operation indicates either: - a switch failure - the lack of that input to the vehicle theft security system module - a failure internal to the module - a faulty horn system Check for continuity at the switch. If this is good, check for an open or shorted wire between the switch and alarm module. Also, check if the Powertrain Control Module (PCM) has been replaced recently. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Vehicle Communication VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate 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 the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver 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 code determines the message that has higher priority, which is then allowed to access the bus first. The two wires 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. 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: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection for diagnostic and repair procedures. Any of the following bus failure messages may be displayed: Short to Battery Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground Either or both of the bus wires are shorted to ground or a specific ground may be open. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2701 Bus (+) & (-) Shorted Together The two bus wires are shorted together. No Termination The bus system has lost connection with all of its terminators. Bus Bias Level Too Low Either or both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High Either or both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias The bus system has lost connection with all modules that provide bias. Bus (+) Open The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open The bus (-) wire has lost connection with termination and/or bias. Not Receiving Bus Messages Correctly The DRB cannot communicate over the bus and does not know why. Wiper System WIPER SYSTEM The front wiper system provides the driver with normal wipe (low and high speeds), intermittent wipe, wiper after wash, and mist wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. Other wiper system features: Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled providing a range of from 1 second to 36 seconds. Mist Wipe When the wiper is in the off position and the driver presses the mist control for more than 125 msec, 1 wipe cycle in low speed mode will be provided. The wipe will continue in low speed as long as the switch is held in that position. Wiper After Wash Mode When the driver presses the wash button for over 3/8 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Body Control Module: Reading and Clearing Diagnostic Trouble Codes Displaying & Reading Trouble Codes CCD Data Link Connector Tip: Reading codes requires the use of a DRBII Diagnostic Readout Box or Equivalent Scan Tool. WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 10 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. NOTE: These diagnostic test procedures have been designed specifically for use with the Chrysler DRBII (Diagnostic Readout Box II). However it should be possible to perform the same tests using an equivalent Scan Tool. NOTE: It is not necessary to perform all of the tests in Diagnostic Charts to diagnose an individual code. Clearing Trouble Codes To clear codes, all codes must be "read," then proceed as follows: 1. After all codes have been read, press ATM. The display will change to the ERASE menu screen. 2. Press "1 ERASE CODES" to erase all codes. The display will return to the airbag menu screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2704 Body Control Module: Component Tests and General Diagnostics Diagnostic Notes - Read First 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. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active code(s). Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. 3.12.1 Active Codes ACTIVE CODES An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. 3.12.2 Stored Codes STORED CODES Airbag codes are automatically stored in the ACM's memory when the ignition is turned off with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2705 If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on," wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Manual A/C (HVAC) - Mode Door Operation MANUAL A/C (HVAC) MODE DOOR OPERATION The DRB trouble codes that indicate a stall failure or a feedback signal failure work together to show what is wrong with the HVAC system. The stall trouble codes mean that the Body Control Module (BCM) cannot force an actuator to the end of the mode door travel. Internal problems in the body control module will set other short-related trouble codes. Having only stall trouble codes indicates that there is a problem with an open or short circuit in the wiring, a bad actuator, a bad mode door or connecting linkage. It is important that the operation of the mode door be checked if an actuator is removed. This can be checked by rotating the door shaft to confirm that the door will stop at both ends of travel. The actuator itself has no stops. It must have the mode door to stop travel to pass the stall test. A feedback signal failure can occur on the mode door. The body control module monitors the feedback signal to check the position of the actuator. The body control module not only checks the level of the signal but also how much the voltage changes. A feedback failure can occur if there is a short or open circuit in the wiring, a bad actuator, a bad body control module, a bad mode door or connecting linkage. The easiest way to diagnose this is to use the DRB to actuate the mode door. Note that the feedback voltage of the actuator should smoothly change as the actuator is moved. A sudden change in the feedback voltage to a 5.0-volt or a 0.0-volt level indicates the actuator is bad. A fixed feedback voltage that is less than 5.0 volts or greater than 0.0 volts without a stall failure, or a short failure indicates that the actuator, the mode door, or a connecting mechanical linkage is jammed preventing movement. A feedback signal voltage that stays on 5.0 volts or 0.0 volts indicates a wiring or body control module problem. The feedback failure trouble code can also occur from a lack of actuator travel. This can be checked by confirming that the feedback signal smoothly changes when the actuator is moved with the DRB. If the signal is ok, the door travel is not correct. The actuator must be removed and the mode door mechanically checked for proper operation. Typical problems that prevent door movement include screws dropped in the A/C unit or warped doors. Replace any part that is found defective. Anytime the voltage to the BCM is interrupted for less than 2 minutes or voltage drops below approximately 10.0 volts (battery disconnected, etc.), it may be necessary to recalibrate the mode door. This can be done by using the DRB, MDS machine or removing the IOD (M1) fuse for 10 seconds, reinstall it and then start the engine. Diagnostic Strategies ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 2706 Body Control Module: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRBIII DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform VEHICLE COMMUNICATION TEST 1A. DRBIII Error Messages DRBIII ERROR MESSAGE Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2707 Body Control Module: Service and Repair JUNCTION BLOCK REMOVAL Junction Block/BCM Location The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. Junction Block and Body Control Module assemblies are located on the driver's side of the vehicle. 1. Open the front driver's door and remove end cap. 2. Remove center bezel. 3. Remove instrument cluster hood. 4. Remove silencer. 5. Remove wire harness connectors from Junction Block. 6. Remove Junction Block three mounting screws. 7. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 8. Disconnect BCM wire connectors and remove the assembly. 9. Remove Junction Block/BCM from vehicle. INSTALLATION - For installation, reverse the above procedures. Ensure that the wire terminals and connectors are in good condition and connectors are properly installed. BODY CONTROL MODULE REMOVAL 1. The Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 2. Remove the two BCM attaching screws and release the two BCM locking latches from the Junction Block. 3. Disconnect BCM from the Junction Block. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2708 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII (diagnostic read-out box) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications Powertrain Control Module: Specifications PCM Mounting screw torque ............................................................................................................... .......................................................... 4 Nm (35 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: Component Locations Fig. 16 Power Distribution Center (PDC) The Powertrain Control Module (PCM) is located in the left front engine compartment close to the transmission control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2714 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2717 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2718 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2719 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2720 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2721 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2722 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2723 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2724 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2725 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2726 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2727 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2728 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2729 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2730 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2731 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2732 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2733 Powertrain Control Module: Connector Views Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2734 PCM Connector View Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2735 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. 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 because of corrosion. - 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. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description Powertrain Control Module: Description and Operation Component Description Fig.9 Power Distribution Center (PDC) The PCM regulates the ignition system. The PCM supplies battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM controls ignition timing by turning on and off a transistor in the distributor. During the crank-start period the PCM maintains spark advance at 9° BTDC. During engine operation the following inputs determine the amount of spark advance provided by the PCM. Intake air temperature. - Coolant temperature. - Engine RPM. - Intake manifold vacuum. The PCM also regulates the fuel injection system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description > Page 2738 Powertrain Control Module: Description and Operation PCM Battery Feed CIRCUIT OPERATION Circuit A14 is used to provide a constant battery feed to the Powertrain Control Module (PCM). This circuit originates in the Power Distribution Center (PDC) and is protected by a 20 Amp fuse located in cavity 5. It is also spliced and provides power for the Automatic Shut Down (ASD) relay, coil and contact sides. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description > Page 2739 Powertrain Control Module: Description and Operation Power (Device) Ground Helpful Information Circuit Z12 which supplies a ground for the PCM high current drivers, terminates at the left strut tower. If the system loses ground for the Z12 circuit the vehicle will not operate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description > Page 2740 Powertrain Control Module: Description and Operation System Operation SYSTEM OPERATION Powertrain Control Module The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. See Charging System/Testing and Inspection/Procedures/On-board Diagnostic System Test. The PCM cannot be repaired and must be replaced if faulty. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Component Tests and General Diagnostics Powertrain Control Module: Component Tests and General Diagnostics Component Testing Testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Diagnostic Charts For Trouble Code charts see Computers and Control Systems/Testing and Inspection/Procedures/Diagnostic Charts. See: Testing and Inspection SBEC Testing No specific procedures are provided to diagnose the SBEC by itself. Please See: Computers and Control Systems, Testing and Inspection. SBEC failure is determined as a result of a related system failure. See: Testing and Inspection Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2743 Powertrain Control Module: Service and Repair Fig. 33 Auxiliary Jumper Terminal POWERTRAIN CONTROL MODULE SERVICE The PCM attaches to a bracket between the air cleaner housing and Power Distribution Center (PDC) Fig. 33. REMOVAL 1. Disconnect negative cable from auxiliary jumper terminal Fig. 33. 2. Disconnect both 40-way connectors from PCM. Fig. 34 PCM Bracket Screws 3. Remove screws attaching PCM to bracket Fig. 34. 4. Lift PCM up to remove it from vehicle. INSTALLATION 1. Install PCM. Tighten mounting screws. 2. Attach both 40-way connectors to PCM. 3. Connect negative cable to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2747 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2748 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2749 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2750 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2751 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, generator field, electronic ignition coil and the heating elements in the oxygen sensors. Refer to Diagrams/Electrical for circuit information. The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. OPERATION The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. When the ignition switch is in On or Start, the PCM momentarily turns on the ASD relay. The PCM also monitors the ASD relay output voltage. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. While the relay is on the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the PDC Fig. 25. The inside top of the PDC cover has label showing relay and fuse identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2752 Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Power for the coil and contact side of the relay is provided by circuit A14. This circuit is HOT at all times and protected by a 20 amp fuse located in cavity 5 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the relay on circuit K51. This circuit connects to cavity 67 of the PCM connector. When the relay is energized, the contacts internal to the relay close connecting circuits A14 and A142. The A142 circuit is spliced and provides power to the fuel injectors, generator, electronic EGR transducer solenoid, and the ignition coil. The A142 circuit is also spliced and connects to the PCM connector, cavity 6. This input is used for ASD sense by the PCM. HELPFUL INFORMATION Check the 20 amp fuse located in cavity 5 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in cavity 5 of the PDC Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 2755 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD Relay Test Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 2756 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 1 ASD And Fuel Pump Relay Terminals OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Electrical Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service Precautions > Page 2761 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located on the rear side of the front bumper beam. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the Powertrain Management/Computers and Control Systems/Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: 1. Disconnect the sensor from the engine harness. 2. Attach ohmmeter leads to the wire terminals of the sensor. 3. At room temperature of 25 °C (75 - 80°F), an ohmmeter reading of 9 K to 11 K ohms should be observed. 4. If reading is above or below the specification, replace the sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2764 Battery Temperature Sensor: Service and Repair REMOVAL 1. Raise vehicle on host. 2. Remove screw from sensor. 3. Disconnect electrical connector from sensor. INSTALLATION 1. Connect electrical connector to sensor. 2. Install screw and tighten. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) Camshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2768 Camshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2769 Camshaft Position Sensor: Description and Operation Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. OPERATION This vehicle is equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. The distributor is also equipped with an internal camshaft position (fuel sync) sensor Fig. 2. This sensor provides fuel injection synchronization and cylinder identification to the PCM. The camshaft position sensor contains a hall effect device called a sync signal generator. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the shutter enters the sync signal generator, the interruption of magnetic field causes the voltage to switch high. This causes a sync signal of approximately 5 volts. When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts. Since the shutter rotates at half crankshaft speed, it may take one engine revolution during cranking for the PCM to determine the position of piston number 6. NO CAM SIGNAL AT PCM FAULT MESSAGE Purpose The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. Operation The sensor is provided with 12 volts from the fused ignition switch output circuit and the powertrain control module supplies a sensor ground. The CMP sensor has a 5 volt pull-up from the PCM. The sensor signal is created when the distributor's pulse ring is rotated past the camshaft position sensor. When Monitored: The crankshaft position sensor signal trouble code is not set. With the ignition in either the start or run position and battery voltage between 4 and 15 volts. Set Condition: Too many crankshaft position sensor signals detected without any camshaft position sensor signal Possible Causes: Open fused ignition switch output circuit (12V) - Open sensor ground - Damaged pulse ring - Failed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2770 - Failed PCM - Inoperative distributor drive - Broken timing belt - Connector terminals - Connector wires Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 2773 Camshaft Position Sensor: Service and Repair The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant temperature sensor torque ..................................................................................................... .......................................................... 27 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2777 Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor And Oil Pressure Switch Locations Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2778 Engine Coolant Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2779 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor is installed in the housing between the filler neck and thermostat Fig. 7. The sensor provides an input voltage to the PCM. The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emissions and improve driveability - Because spark advance changes at different engine operating temperatures during warm-up, all spark advance testing should be done with the engine fully warmed. The PCM demands slightly richer air-fuel mixtures and higher idle speeds until the engine reaches normal operating temperature. The engine coolant sensor input is also used for radiator fan control. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. This sensor input is also used for the instrument cluster coolant temperature gauge. From circuit K2, the engine coolant temperature sensor draws up to 5 volts from the PCM. The sensor is a variable resistor. As coolant temperature changes the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 4 Engine Coolant Temperature Sensor 1. With key off, disconnect wire connector from engine coolant temperature sensor Fig. 4. 2. Connect one lead of ohmmeter to one terminal of engine coolant temperature sensor. 3. Connect the other lead of ohmmeter to remaining terminal of engine coolant temperature sensor. The ohmmeter should read as follows; - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F, ohmmeter should read approximately 7,000 to 13,000 ohms. 4. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between connector terminal 43 and the sensor harness connector. Refer to Wiring Diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2782 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2783 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 1 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located next to the thermostat housing Fig. 1. REMOVAL 1. Drain cooling system until coolant level is below engine coolant temperature sensor. Refer to Cooling System. 2. Disconnect electrical connector from sensor. 3. Remove sensor from engine. INSTALLATION 1. Install ECT sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor screw torque ................................................................................................................................................... 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2787 Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2788 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2789 Crankshaft Position Sensor: Description and Operation Fig. 5 Timing Slots Fig. 3 Crankshaft Position Sensor--Adjustable Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2790 Fig 12 Crankshaft Position Sensor Location -- Typical OPERATION The crankshaft position sensor Fig. 3 detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots Fig. 5. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. - The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. - It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The sensor connector has a Christmas tree attached to the heater tube bracket. - The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On automatic transmission vehicles this circuit is spliced and provides an input to the Transmission Control Module (TCM). The PCM provides a ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. HELPFUL INFORMATION The K7 circuit supplies 8 volts to the distributor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 9 Crankshaft Position Sensor REMOVAL 1. Remove speed control servo from driver's side strut tower. 2. Remove crankshaft position sensor retaining bolt Fig. 9. 3. Pull crankshaft position sensor straight up out of the transaxle housing. 4. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. INSTALLATION - ADJUSTABLE Some vehicles may be equipped with an adjustable crankshaft position sensor. This can be identified by an elongated mounting hole in the sensor. Fig. 10 Crankshaft Position Sensor And Spacer If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor Fig. 10. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 2. Connect crankshaft position sensor electrical connector to the wiring harness connector. 3. Attach connector to heater tube bracket. 4. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. INSTALLATION - NON-ADJUSTABLE 1. Install sensor in transaxle. 2. Install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. 4. Attach connector to heater tube bracket. 5. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2795 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel level input comes across the CCD bus from the body control module. this input is used for the Fuel System and Misfire Monitors. If the fuel level is below approximately 1/16th of a tank the Fuel System and Misfire monitors will be disabled. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake air temperature sensor torque ....................................................................................................................................................... 11.5 Nm (100 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2802 Fig. 21 Intake Air Temperature Sensor And MAP Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2803 Intake Air Temperature Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2804 Intake Air Temperature Sensor: Description and Operation Fig. 11 Intake Air Temperature Sensor And MAP Sensor PURPOSE The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. OPERATION The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. - At high temperatures, resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to cavity 37 of the PCM connector. The IAT sensor threads into the intake manifold Fig. 11. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. The K21 circuit connects to cavity 37 of the PCM connector. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground path for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Component Testing Intake Air Temperature Sensor: Testing and Inspection Component Testing Fig. 5 Intake Air Temperature Sensor And MAP Sensor NOTE: To perform a complete test of this sensor and its circuit, SEE System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from the intake air temperature sensor Fig. 5. 2. Connect a high input impedance (digital) volt-ohmmeter to the sensor terminals. The ohmmeter should read as follows: - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 37 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. Refer to Electrical Diagrams for circuit information. - If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2807 Intake Air Temperature Sensor: Service and Repair Fig. 21 Intake Air Temperature Sensor And MAP Sensor The intake air temperature sensor threads into the intake manifold plenum Fig. 21. REMOVAL 1. Remove electrical connector from sensor. 2. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2812 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP sensor torque .............................................................................................................................. ....................................................... 3.4 Nm (30 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2813 Fig. 21 Intake Air Temperature Sensor And MAP Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2814 Map Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2815 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 5 Intake Air Temperature Sensor And MAP Sensor OPERATION The MAP sensor reacts to absolute pressure in the intake manifold and provides an input voltage to the PCM. The PCM interprets the MAP sensor input as engine load. The input voltage level supplies the PCM with information relating to ambient barometric pressure during engine start-up (cranking) and engine load while its operating. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. The PCM supplies 5 volts direct current to the MAP sensor. The MAP sensor converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. At key on, before the engine is started, the PCM determines atmospheric air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The sensor is mounted on the intake manifold Fig. 1. The sensor is connected to the throttle body or intake manifold with a vacuum hose and to the PCM electrically CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Manifold Absolute Pressure (MAP) sensor Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides a ground path for the MAP signal (circuit K1) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 30 MAP Sensor Connector NOTE: Complete testing of this component and its circuit is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 3 (Fig. 30). - With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. - The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. - If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 29 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 51. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (+/0.5V). Five volts (+/-0.5V) should also be at terminal 43 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. NOTE: Complete testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2818 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 volts to the A/C pressure switch and the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Throttle position sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2819 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 21 Intake Air Temperature Sensor And MAP Sensor The MAP sensor attaches to the intake manifold plenum Fig. 21. REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove sensor mounting screws. 3. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seal. 2. Tighten mounting screws to 3.4 Nm (30 in. lbs.) torque. 3. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle Technical Service Bulletin # 18-01-98 Date: 980116 MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle NO: 18-01-98 GROUP: Driveability DATE: Jan. 16, 1998 SUBJECT: MIL Illumination with Hex Code $3E, Possible Sags/Hesitations/Rough Idle MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: MIL illumination with hex code $3E - UPSTREAM O2 SENSOR SHORTED TO VOLTAGE along with possible symptoms of sags/hesitation or rough idle. NOTE: HEX CODE $3E MUST BE SEEN TO PERFORM THIS REPAIR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-94-TF-91 0.4 Hrs. FAILURE CODE: P8 - New Part 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 DTC $3E is present, follow the diagnostic procedure in the applicable diagnostic manual. If no apparent reason is found for the DTC, perform the Repair Procedure. Parts/Equipment Required 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable AR (1) 05010885AA Kit, Oxygen Sensor Jumper (4-cyl & 96/97 6-cyl) AR (1) 05010934AA Kit, Oxygen Sensor Jumper (1995 6-cyl) AR 04778570 Heat Shrink Tubing AR (1) 04778138 Tape, Cloth Underhood Electrical 1 NPN Soldering Iron 1 NPN Rosin Core Solder Repair Procedures This bulletin involves cutting and splicing a jumper from the oxygen sensor(s) to the powertrain control module. Single Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector and disconnect it. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2828 3. Identify the sensor ground terminal. For 1997 models it is terminal No. 3, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). For 1995/1996 models it is terminal No. 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1997 connectors use a rear secondary lock latch at the rear side of the connector. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 3 by carefully pulling from the rear while spreading the two locking fingers. 1995/1996 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal No. 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out from the rear. 5. Choose the terminal on the end of the repair lead p/n 05010885AA that matches the removed terminal. Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. NOTE: THE TERMINAL END ON THE OPPOSITE END OF THE NEW LEAD IS FOR THE OTHER APPLICABLE YEAR VEHICLES. THIS TERMINAL MUST BE CLIPPED OFF. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2829 8. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 9. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 10. Cut the k4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 11. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. 12. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 13. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 14. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 15. Reconnect the battery negative cable. 16. Verify the wiring repair by running the oxygen sensor test with the DRB III. Double Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector # 1 and disconnect it. 3. Identify the sensor ground terminal. For 1995 models, it is terminal # 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1995 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal # 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out form the rear. 5. Choose the terminal on the end of the repair lead p/n 05010934AA that has the longer length of wire from the Y splice (1100 mm). Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Repeat steps 3 through 6 for the upstream oxygen sensor No. 2, using the other lead from the Y spliced repair jumper. 8. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. 9. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 10. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 11. Cut the K4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2830 13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 14. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 15. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 16. Reconnect the battery negative cable. 17. Verify the wiring repair by running the oxygen sensor test with the DRB III. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle Technical Service Bulletin # 18-01-98 Date: 980116 MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle NO: 18-01-98 GROUP: Driveability DATE: Jan. 16, 1998 SUBJECT: MIL Illumination with Hex Code $3E, Possible Sags/Hesitations/Rough Idle MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: MIL illumination with hex code $3E - UPSTREAM O2 SENSOR SHORTED TO VOLTAGE along with possible symptoms of sags/hesitation or rough idle. NOTE: HEX CODE $3E MUST BE SEEN TO PERFORM THIS REPAIR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-94-TF-91 0.4 Hrs. FAILURE CODE: P8 - New Part 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 DTC $3E is present, follow the diagnostic procedure in the applicable diagnostic manual. If no apparent reason is found for the DTC, perform the Repair Procedure. Parts/Equipment Required 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable AR (1) 05010885AA Kit, Oxygen Sensor Jumper (4-cyl & 96/97 6-cyl) AR (1) 05010934AA Kit, Oxygen Sensor Jumper (1995 6-cyl) AR 04778570 Heat Shrink Tubing AR (1) 04778138 Tape, Cloth Underhood Electrical 1 NPN Soldering Iron 1 NPN Rosin Core Solder Repair Procedures This bulletin involves cutting and splicing a jumper from the oxygen sensor(s) to the powertrain control module. Single Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector and disconnect it. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2836 3. Identify the sensor ground terminal. For 1997 models it is terminal No. 3, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). For 1995/1996 models it is terminal No. 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1997 connectors use a rear secondary lock latch at the rear side of the connector. Use a terminal pick or large paper clip and depress the latch while carefully pulling the rear secondary cap off the connector. Remove terminal No. 3 by carefully pulling from the rear while spreading the two locking fingers. 1995/1996 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal No. 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out from the rear. 5. Choose the terminal on the end of the repair lead p/n 05010885AA that matches the removed terminal. Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. NOTE: THE TERMINAL END ON THE OPPOSITE END OF THE NEW LEAD IS FOR THE OTHER APPLICABLE YEAR VEHICLES. THIS TERMINAL MUST BE CLIPPED OFF. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2837 8. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 9. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 10. Cut the k4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 11. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. 12. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 13. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 14. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 15. Reconnect the battery negative cable. 16. Verify the wiring repair by running the oxygen sensor test with the DRB III. Double Upstream 02 Sensor 1. Disconnect the battery negative lead. 2. Locate the upstream oxygen sensor connector # 1 and disconnect it. 3. Identify the sensor ground terminal. For 1995 models, it is terminal # 1, K4 circuit, 18 gauge black with a light blue tracer (Figure 1). 4. 1995 connectors use a front loaded secondary lock wedge connector. Remove the lock wedge by using a paper clip as a hook. Remove terminal # 1 by depressing the connector lock finger with a terminal pick or paper clip while pulling the terminal out form the rear. 5. Choose the terminal on the end of the repair lead p/n 05010934AA that has the longer length of wire from the Y splice (1100 mm). Insert the new terminal and wire lead into the vacant cavity of the oxygen sensor connector. Assemble the connector by reversing the connector disassembly procedure. 6. Fold the removed oxygen sensor terminal onto itself and place a piece of heat shrink tubing p/n 04778570 over the wire end. Shrink with a heat gun until sealant flows from both ends. Tape the removed wire out of the way. 7. Repeat steps 3 through 6 for the upstream oxygen sensor No. 2, using the other lead from the Y spliced repair jumper. 8. Tape wrap the new lead neatly to the wiring harness and route it up to the powertrain control module. 9. Disconnect the powertrain control module C1 connector (Figure 2). Unwrap the tape as required to expose the insulation 3 to 4 inches behind the connector. 10. Remove the wire dress cover from the rear of the C1 connector. Locate cavity 43 of the connector (K4 circuit BK/LB, Figure 2). 11. Cut the K4 wire 1-1/2 inches from the C1 connector. Strip both ends of the cut wire and the end of the new lead. 12. Slip a piece of heat shrink tube p/n 04778570 over the lead connected to the C1 connector. Make sure the shrink tube is long enough to seal the splice after soldering. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-01-98 > Jan > 98 > MIL ON, Hex Code $3E, Sag/Hesitation/Rough Idle > Page 2838 13. Twist all three leads together and solder the splice with rosin core solder. Slide the heat shrink tube over the splice and shrink with a heat gun until sealant flows from both ends of the shrink tubing. 14. Reinstall the wire dress cover to the rear of the C1 connector. Using electrical tape p/n 04778138, tape over the repaired area to match the original construction of the harness finishing the tape on the tape flange of the wire dress cover. 15. Reconnect the oxygen sensor to its harness and the C1 connector to the powertrain control module. 16. Reconnect the battery negative cable. 17. Verify the wiring repair by running the oxygen sensor test with the DRB III. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2839 Oxygen Sensor: Specifications - After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. - If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite (R) 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. - Tighten the sensor to 28 Nm (20 ft. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2842 Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2843 Fig 12 Upstream Heated Oxygen Sensor 1/1 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Front Upstream Oxygen Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor > Page 2846 Downstream Oxygen Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2847 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2848 Oxygen Sensor: Description and Operation Fig 12 Upstream Heated Oxygen Sensor 1/1 OPERATION As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic converter, one downstream of the converter. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The automatic shutdown relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 0.1 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 1.0 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop. the PCM adjusts injector pulse width based on preprogrammed (fixed values and inputs from other sensors. The upstream oxygen sensor threads into the outlet flange of the exhaust manifold (Fig. 12). Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2849 DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig. 13). The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. CIRCUIT OPERATION Circuit A14 is connected to the BUS bar in the Power Distribution Center (PDC), which connects to battery voltage. The contact side of the Automatic Shut-Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse, located in cavity 5 of the PDC, protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM. The A142 circuit also splices to cavity 6 of the PCM connector. The input by circuit A142 tells the PCM that the ASD relay is energized. The A142 circuit supplies voltage for the upstream heated oxygen sensor and circuit F142 supplies voltage to the downstream heated oxygen sensor. The F142 circuit is protected by a 10 Amp fuse located in cavity 1 of the PDC. Power for the fuse is supplied by circuit A142. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the downstream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream (left) and downstream (right) heated oxygen sensor signals (circuits K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Circuit Z1 provides the ground path for the heater circuits in the sensors. This ground terminates at the right frame rail. Circuit K4 splices to supply ground for the signals for the following: Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Vehicle speed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, distributor, ASD relay, generator, and the EGR solenoid. The PCM controls the ground path for each of the components powered by circuit A142. Circuit K4 splices to supply ground for the signals for the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Vehicle speed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2852 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 5 and 7 ohms. NOTE: This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. NOTE: Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS ONLY (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 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 connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See, sensor heating element test. 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. NOTE: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 2853 Oxygen Sensor: Service and Repair Fig 89 Upstream Oxygen Sensor REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector from sensor. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 89). INSTALLATION 1. After removing the sensor the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. - If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. - Tighten the sensor to 28 Nm (20 ft lb) torque. 2. Connect electrical connector to sensor. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 2854 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revision NUMBER: 26-10-96 GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus, Stratus & Breeze - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs 8W-80-44 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2859 8W-80-45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2860 8W-80-46 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 2861 8W-80-47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2864 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2865 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2866 Power Steering Pressure Switch: Description and Operation Fig. 21 Power Steering Pressure Switch PURPOSE On some vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. OPERATION The pressure switch improves vehicle idle quality, by maintaining required engine idle speed when necessary, do to increased pressure in the power steering system. This increased pressure will slow down the power steering pump which will decrease engine idle speed. The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear on vehicle's requiring its usage. When power steering pump pressure exceeds 4137 kPa (600 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z1 provides a ground for the power steering pressure switch. The ground is terminated at the left strut tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2867 Power Steering Pressure Switch: Service and Repair REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on the back side of the power steering gear. 4. Remove the vehicle's wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Output Voltage At idle ................................................................................................................................................... ...................................... greater than 0.6 volts At wide open throttle (WOT) ........................................................................................................................................................... less than 4.5 volts Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2872 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2873 Fig. 23 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2874 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2875 Throttle Position Sensor: Description and Operation Fig. 23 Throttle Position Sensor PURPOSE Along with inputs from other sensors, the PCM uses TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the PCM) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to a maximum of 3.7 volts at wide open throttle. The throttle position sensor mounts to the side of the throttle body Fig. 23. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides a ground path for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 Volts to the A/C pressure switch and the map sensor. On automatic transmission vehicles, circuit K22 is spliced and provides an input to the Transmission Control Module (TCM). Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2878 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be greater than 0.6 volts. - At wide open throttle, TPS output voltage should be less than 4.5 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2879 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2880 Throttle Position Sensor: Service and Repair Fig. 37 Throttle Position Sensor The TPS attaches to the side of the throttle body Fig. 37. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and TPS. 3. Remove throttle body. 4. Remove TPS mounting screws. 5. Remove throttle position sensor. Fig. 38 Indexing Throttle Position Sensor INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 38. - The socket has two tabs inside it. The throttle shaft rests against the tabs. - When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. - The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. - Tighten mounting screws to 2 Nm (17 in. lbs.) torque. NOTE: After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 2. Install throttle body to intake manifold. 3. Attach electrical connectors to idle air control motor and throttle position sensor. 4. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2889 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2890 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2891 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2897 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2898 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2903 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2904 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2905 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2911 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2912 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2913 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2916 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2917 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2918 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2919 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 2920 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2926 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2927 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2928 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2929 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2930 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2931 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2932 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2933 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2934 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2935 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2936 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2937 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2938 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2939 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2940 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2941 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2942 Vehicle Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2943 Vehicle Speed Sensor: Description and Operation TRANSMISSION CONTROL MODULE -- AUTO TRANS -- PCM INPUT The Transmission Control Module (TCM) supplies 3 inputs to the PCM: Vehicle Speed (road speed) - Torque Management - Gear Position VEHICLE SPEED The TCM supplies vehicle speed and distance traveled inputs to the PCM. From these inputs and the throttle position sensor input, the PCM determines when a deceleration condition occurs. TORQUE MANAGEMENT The PCM receives a torque management input from the TCM. The PCM receives the input when the transmission shifts gears. In response, the PCM shuts off a number of fuel injectors when the transmission shifts gears. Fig. 24 Vehicle Speed Sensor--Manual Transmission VEHICLE SPEED SENSOR - PCM INPUT (MANUAL TRANSMISSION) The vehicle speed sensor is located in the transmission extension housing Fig. 24. The sensor input is used by the PCM to determine vehicle speed and distance traveled, manual transmission only. Refer to Transmission Control Module for automatic transmission. The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate the following functions or systems: Speedometer - Speed Control - Daytime Running Lights (Canadian Vehicles Only) - Open Throttle IAC position. CIRCUIT OPERATION On vehicles equipped with the manual transmission, a Vehicle Speed Sensor (VSS) located in the transmission is used. Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the VSS. The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7, from the VSS, provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides a ground path for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 is spliced and provides an input to the Body Control Module (BCM) for vehicle speed. Circuit K4 splices to supply ground for the signals for the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2946 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 100). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor. 2. Install mounting bolt. 3. Connect electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Shift Light > Component Information > Description and Operation Shift Light: Description and Operation On vehicles equipped with a manual transmission an up-shift lamp is used. This alerts the operator when the transmission should be shifted to a higher gear. The Powertrain Control Module (PCM) sends a signal to the Body Control Module (BCM) over the CCD Bus requesting lamp illumination. To determine if lamp illumination is required the PCM looks at several items including throttle position and vehicle speed. When the BCM receives this request it processes it and sends the signal over the CCD Bus to the instrument cluster for lamp illumination. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Output Voltage At idle ................................................................................................................................................... ...................................... greater than 0.6 volts At wide open throttle (WOT) ........................................................................................................................................................... less than 4.5 volts Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2954 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2955 Fig. 23 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2956 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2957 Throttle Position Sensor: Description and Operation Fig. 23 Throttle Position Sensor PURPOSE Along with inputs from other sensors, the PCM uses TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the PCM) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to a maximum of 3.7 volts at wide open throttle. The throttle position sensor mounts to the side of the throttle body Fig. 23. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides a ground path for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 Volts to the A/C pressure switch and the map sensor. On automatic transmission vehicles, circuit K22 is spliced and provides an input to the Transmission Control Module (TCM). Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2960 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be greater than 0.6 volts. - At wide open throttle, TPS output voltage should be less than 4.5 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2961 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2962 Throttle Position Sensor: Service and Repair Fig. 37 Throttle Position Sensor The TPS attaches to the side of the throttle body Fig. 37. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and TPS. 3. Remove throttle body. 4. Remove TPS mounting screws. 5. Remove throttle position sensor. Fig. 38 Indexing Throttle Position Sensor INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 38. - The socket has two tabs inside it. The throttle shaft rests against the tabs. - When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. - The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. - Tighten mounting screws to 2 Nm (17 in. lbs.) torque. NOTE: After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 2. Install throttle body to intake manifold. 3. Attach electrical connectors to idle air control motor and throttle position sensor. 4. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Torque Reduction Signal > Component Information > Description and Operation Torque Reduction Signal: Description and Operation TORQUE MANAGEMENT INPUT Circuit T10 connects from the Transmission Control Module (TCM) to the Powertrain Control Module (PCM) cavity 63. This is the torque management request from the TCM to the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2974 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2975 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2976 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2982 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2983 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2988 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2989 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2990 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2996 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 2997 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2998 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3001 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3002 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3003 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3004 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3005 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3025 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3026 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3027 Vehicle Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3028 Vehicle Speed Sensor: Description and Operation TRANSMISSION CONTROL MODULE -- AUTO TRANS -- PCM INPUT The Transmission Control Module (TCM) supplies 3 inputs to the PCM: Vehicle Speed (road speed) - Torque Management - Gear Position VEHICLE SPEED The TCM supplies vehicle speed and distance traveled inputs to the PCM. From these inputs and the throttle position sensor input, the PCM determines when a deceleration condition occurs. TORQUE MANAGEMENT The PCM receives a torque management input from the TCM. The PCM receives the input when the transmission shifts gears. In response, the PCM shuts off a number of fuel injectors when the transmission shifts gears. Fig. 24 Vehicle Speed Sensor--Manual Transmission VEHICLE SPEED SENSOR - PCM INPUT (MANUAL TRANSMISSION) The vehicle speed sensor is located in the transmission extension housing Fig. 24. The sensor input is used by the PCM to determine vehicle speed and distance traveled, manual transmission only. Refer to Transmission Control Module for automatic transmission. The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate the following functions or systems: Speedometer - Speed Control - Daytime Running Lights (Canadian Vehicles Only) - Open Throttle IAC position. CIRCUIT OPERATION On vehicles equipped with the manual transmission, a Vehicle Speed Sensor (VSS) located in the transmission is used. Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the VSS. The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7, from the VSS, provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides a ground path for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 is spliced and provides an input to the Body Control Module (BCM) for vehicle speed. Circuit K4 splices to supply ground for the signals for the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Crankshaft position sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 3031 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 100). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor. 2. Install mounting bolt. 3. Connect electrical connector to sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications Voltage Signal: Specifications The PCM tries to maintain system voltage between 12.9 volts and 15.0 volts. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Locations > Component Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Locations > Component Locations > Page 3037 Generator And A/C Compressor Connections Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation Voltage Signal: Description and Operation Description of Operation THEORY OF OPERATION: The PCM monitors battery voltage input to determine fuel injector pulse width and generator field control voltage. Injector Pulse Width If voltage is low the PCM will increase pulse width (the period of time that the injector is energized). Battery Temperature Sensor The PCM uses the temperature of the battery area to control the charge rate. The signal is used to regulate the system voltage. The system voltage is higher at cold temperatures and is gradually reduced as temperature is increased. Generator Field Voltage The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called "control" voltage. This control voltage is determined from the battery temp sensor for ambient sensor and the sensed voltage system voltage at PCM pin # 11. The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage the PCM will supply more ground to the field circuit. - If the sensed voltage is more than the control voltage the PCM will supply less ground to the field circuit. NAME OF CODE: Charging System Voltage Too High When Monitored: With the ignition key ON and the engine running above 1500 RPM for 1 minute. Set Condition: This trouble code sets when the Powertrain Control Module (PCM) tries to regulate the generator field and there are no detected field problems but, the sensed battery voltage continues to increase. Possible Causes: Generator internal short - Generator field driver short to ground - The sensed battery voltage is less than actual - Powertrain control module failure NAME OF CODE: Charging System Voltage Too Low When Monitored: With the ignition key ON and the engine running above 1500 RPM for 1 minute. Set Condition: With no other charging system codes set. The battery sensed voltage is below the charging goal. The PCM senses the battery voltage, turns off the field driver and senses the battery voltage again. If the voltages are the same the code is set. Possible Causes: Defects in generator drive belt or adjustment - High resistance between battery B(+) and generator B(+) - High resistance between battery B(-) and generator B(-) - PCM failure NAME OF CODE: Generator Field Not Switching Properly When Monitored: With the ignition key ON and the engine running. Set Condition: This trouble code sets when the Powertrain Control Module (PCM) tries to regulate the generator field with no result during monitoring. Possible Causes: Field driver circuit open or shorted - Generator internal open or short - Powertrain control module failure Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation > Page 3040 Voltage Signal: Description and Operation Battery Temperature Sensor PURPOSE The PCM uses the temperature of the battery area to control the charge rate. OPERATION The signal is used to regulate the system voltage. The system voltage is higher at cold temperatures and is gradually reduced as temperature is increased. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Locations Fig. 1 Exhaust System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Locations > Page 3045 Catalytic Converter: Service Precautions The combustion reaction caused by the catalyst releases additional heat in the exhaust system, causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders if exhaust system is equipped with a catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning the catalyst core. Do not allow engine to operate above 1,200 RPM in neutral for extended periods over 5 minutes. This condition may result in excessive exhaust system /floor pan temperatures because of no air movement under the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter Operation Catalytic Converter: Description and Operation Catalytic Converter Operation PURPOSE The three-way catalytic converter, together with the closed loop air-fuel ratio control (based on the oxygen sensor signal) oxidizes carbon monoxides (CO) and hydrocarbons (HC), and reduces nitrogen oxides (NOx). When the mixture is controlled at stoichiometric air-fuel ratio, the three-way catalytic converter provides the highest purification against CO, HC, and NOx. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter Operation > Page 3048 Catalytic Converter: Description and Operation Catalytic Converter Efficiency Failure NAME OF CODE: Catalytic Converter Efficiency Failure WHEN MONITORED: After engine warm up to 170°F, 180 seconds of closed loop operation, open throttle, at a speed >20 mph, with the engine at 1560 - 2460 RPM and MAP at 270 - 380 mm Hg (10.5 - 15 in Hg). SET CONDITION: As the converter loses the ability to store oxygen, efficiency drops, and the concentration of oxygen becomes the same downstream as upstream. The output voltage of the downstream O2S copies that of the upstream sensor with a time lag (seen by the Powertrain Control Module (PCM)) between the switching of the O2S's. The Malfunction Indicator lamp (MIL) illuminates after 2 trips and remains ON, but goes out if the conditions that set the trouble code are not found on subsequent trips. THEORY OF OPERATION: The catalyst monitor uses oxygen sensors (O2S's) to monitor the efficiency of the converter. The dual O2S strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter. As the converter absorbs the oxygen, there is a lack of oxygen downstream of the converter and the output of the downstream O2S indicates limited activity. The downstream O2S detects oxygen content in treated gases that passed the converter. The PCM monitors lean-to-rich switches of the dual O2S's. A ratio of downstream to upstream switches closer to 0 indicates an operational catalyst, while a 1:1 ratio indicates an ineffective catalyst. PROBABLE CAUSES: - Catalytic converter - Exhaust leaks upstream of catalyst - Contaminated fuel - Mechanical engine problem Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3049 Catalytic Converter: Testing and Inspection INSPECTION Inspect for damage, cracking or deterioration. Replace the catalytic converter if obvious damage is found. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Removal Catalytic Converter: Service and Repair Removal 1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed. 2. Remove clamp and supports at muffler to resonator assembly. Remove muffler from resonator pipe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Removal > Page 3052 3. Remove ground strap. 4. Remove clamp and supports at the resonator pipe to catalytic converter slip joint. Separate at slip joint and remove the resonator assembly. 5. Disconnect downstream heated oxygen sensor from the catalytic converter pipe. 6. Disconnect upstream heated oxygen sensor. 7. Remove catalytic converter to exhaust manifold attaching fasteners. Remove catalytic converter from vehicle. 8. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used; ^ To insure proper alignment with other parts in the system. ^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Removal > Page 3053 Catalytic Converter: Service and Repair Installation NOTE: When assembling exhaust system do not tighten clamps until components are aligned and supports have equal load on them. 1. Assemble catalytic convertor to exhaust manifold connection. 2. Assemble resonator pipe to catalytic convertor and attach to the supports on the underbody. 3. Install the muffler to resonator pipe and attach to the supports on the underbody. 4. Working from the front of system; 5. Align and tighten the catalytic convertor to exhaust manifold fasteners to a torque of 32 Nm (24 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Removal > Page 3054 6. Align each component to maintain position and proper clearance with underbody parts and that all supports have equal load on them. Tighten clamps to 80 Nm (60 ft. lbs.). 7. Connect ground strap. 8. Connect the downstream heated oxygen sensor. 9. Connect the upstream heated oxygen sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications Solenoid Coil Resistance @ 20°C (68°F) ......................................................................................................................................................... 25 - 35 ohms Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3059 Canister Purge Solenoid: Locations Purge Solenoid Location Fig. 3 Duty Cycle EVAP Purge Solenoid-Master Cylinder Removed The purge solenoid is located near the left strut tower, under the master cylinder. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3060 EVAP Purge Solenoid Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3061 Canister Purge Solenoid: Description and Operation Fig. 26 Duty Cycle EVAP Purge Solenoid PURPOSE The duty cycle EVAP purge solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. OPERATION During the cold start warm-up period and the hot start time delay the PCM does not energize the solenoid. When de-energized, no vapors are purged. The engine enters closed loop operation after it reaches a specified temperature and the programmed time delay ends. During closed loop operation, the PCM energizes and de-energizes the solenoid 5 to 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time the solenoid is energized. The solenoid attaches to a bracket on the driver's side strut tower Fig. 26. To operate correctly, the solenoid must be installed with the electrical connector on top. CIRCUIT OPERATION Circuit F18 supplies battery voltage to the duty cycle EVAP/Purge solenoid. This circuit is HOT in the START and RUN position only. It is also spliced and provides power for the Anti-Lock warning lamp, A/C clutch relay, and high speed radiator fan relay. Circuit F18 connects to the Power Distribution Center (PDC), cavity 9, and is protected by a 10 amp fuse. Power for the fuse is supplied on circuit A21 from the ignition switch. Circuit A1 provides power for the A21 circuit and is protected by a 20 amp fuse located in cavity 8 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the solenoid on circuit K52. Circuit K52 connects to cavity 68 of the PCM connector. HELPFUL INFORMATION - Check the 10 amp fuse located in cavity 9 of the PDC. - Check the 20 amp fuse located in cavity 8 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > EVAP Purge Solenoid Inspection Canister Purge Solenoid: Testing and Inspection EVAP Purge Solenoid Inspection EVAPORATIVE EMISSION PURGE SOLENOID INSPECTION NOTE: When disconnecting the vacuum hose, place an identification mark on it for proper re-connection. 1. Disconnect the vacuum hose from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve. 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve. Battery Voltage / Normal Condition. Applied ....................................................................................... .......................................................................................................... Vacuum Leaks Not Applied ...... .............................................................................................................................................................. ............. Vacuum Maintained 5. Measure the resistance between the terminals of the solenoid valve. - Standard value: 25-35 ohms [at 20°C (68°F)] Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > EVAP Purge Solenoid Inspection > Page 3064 Canister Purge Solenoid: Testing and Inspection Helpful Information - Check the 10 amp fuse located in the junction block. - Check the 20 amp fuse located in cavity 8 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > Page 3065 Canister Purge Solenoid: Service and Repair Fig. 3 Duty Cycle EVAP Purge Solenoid-Master Cylinder Removed REMOVAL 1 If equipped with speed control, remove speed control servo and bracket. Cover the ends of the speed control servo studs to allow easier service of the purge solenoid. 2. Disconnect electrical connector from solenoid. 3. Disconnect vacuum tubes from solenoid. 4. Remove solenoid from bracket by pulling up on solenoid. NOTE: To eliminate a chance of transmitting noises into the body, make sure the hood release cable is installed in all of its clamps. Make sure the solenoid is not touching a brake line. NOTE: The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly. INSTALLATION 1. Install solenoid on bracket. 2. Connect vacuum tube to solenoid. 3. Connect electrical connector to solenoid. 4. Install speed control servo and bracket. Tighten nuts to 9 Nm (80 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Fig 2 EVAP Canister The canister mounts to a bracket behind the front fascia on the passengers side of the vehicle (Fig. 2). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3069 Evaporative Emission Control Canister: Description and Operation Fig 2 EVAP Canister EVAPORATION CONTROL SYSTEM The evaporation control system prevents the emission of fuel tank vapors into the atmosphere. When fuel evaporates in the fuel tank, the vapors pass through vent hoses or tubes to a charcoal canister. The canister temporarily holds the vapors. Through the duty cycle EVAP purge solenoid, the PCM allows intake manifold vacuum to draw vapors from the charcoal canister into the combustion chambers during certain operating conditions. The solenoid regulates vapor flow from the canister to the engine. The evaporative system uses specially manufactured hoses. If they need replacement, only use original equipment fuel vapor resistant hose. EVAP CANISTER All vehicles use a sealed, maintenance free, evaporative (EVAP) canister. Fuel tank pressure vents into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The powertrain control module (PCM) purges the canister through the duty cycle EVAP purge solenoid. The PCM purges the canister at predetermined intervals and engine conditions. The canister mounts to a bracket behind the front fascia on the passengers side of the vehicle (Fig. 2). The vacuum and vapor tube connect to the top of the canister. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - Leak Detection Pump R & I Revisions Leak Detection Pump: Technical Service Bulletins Emissions - Leak Detection Pump R & I Revisions NUMBER: 26-07-98F GROUP: Miscellaneous DATE: July, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus/Stratus/Breeze Service Manual - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Revision to the Leak Detection Pump removal and installation procedures 25-20 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - Leak Detection Pump R & I Revisions > Page 3074 25-21 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - Leak Detection Pump R & I Revisions > Page 3075 Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump Misdiagnosis NUMBER: 18-01-00 GROUP: Vehicle Performance DATE: Feb. 4, 2000 SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR P0456 MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck 1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA) Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH) Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ) GrandCherokee DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494 (LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply vacuum lines examined for pinches or kinks prior to any LDP component replacement. The supply vacuum lines should be checked from the engine compartment all the way to the fuel tank, including the LDP and purge system. NOTE: VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Vacuum Pump Leak Detection Pump: Locations Vacuum Pump Fig 14 Evaporative Canister Attachment Nuts Leak Detection Pump NOTE: The Leak Detection Pump is located under the right front headlamp behind the front fascia. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Vacuum Pump > Page 3078 Leak Detection Pump: Locations Vacuum Test Port EVAP System Service Port EVAP System Service Port Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 3079 Leak Detection Pump Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 3080 Leak Detection Pump: Description and Operation VAPOR CANISTER LEAK DETECTOR CIRCUIT OPERATION Power for the vapor canister leak detector is provided on circuit F18. This circuit is protected by a 10 amp fuse located in cavity 9 of the Power Distribution Center (PDC). Power for the fuse is supplied on circuit A21 from the ignition switch. Circuit A21 is HOT in the START and RUN positions only. The Powertrain Control Module (PCM) controls the ground path for the leak detection pump solenoid and leak detection pump switch. Circuit K106 is connected to cavity 77 of the PCM connector and to the leak detection solenoid. Circuit K107 is connected to cavity 72 of the PCM connector and to the leak detection pump switch. HELPFUL INFORMATION - Check the 10 amp fuse located in cavity 9 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 3081 Leak Detection Pump: Service and Repair The content of this article reflects changes called for in TSB 26-07-98. NOTE: The Leak Detection Pump is located under the right front headlamp behind the front fascia. REMOVAL 1. Disconnect negative cable from auxillary jumper terminal. 2. Raise vehicle on hoist and support. 3. Remove right front wheel. 4. Reposition the wheel well splash shield, passenger side. 5. Loosen the front fascia on passenger side, remove about half of the retainers. 6. Remove washer bottle from vehicle. 7. Remove vacuum lines and hoses from LDP and EVAP canister. Fig 18 LDP Pump And Filter 8. Remove electrical connector from the LDP pump. 9. Remove bracket with LDP pump and EVAP canister as an assembly. 10. Remove LDP pump from bracket. INSTALLATION 1. Install LDP and bracket and tighten the bolts. 2. Connect electrical connector to LDP pump. 3. Install hoses and vacuum lines to EVAP canister and LDP pump. 4. Install EVAP canister and LDP pump to vehicle. 5. Install washer bottle. 6. Install wheel well splash shield. 7. Install front fascia. 8. Install wheel. 9. Lower vehicle. 10. Use the DRB to test the LDP and system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations Fig. 29 EGR Control Valve Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations > Page 3086 EGR Backpressure Transducer: Description and Operation Fig. 27 Electronic EGR Transducer Fig. 29 EGR Control Valve The Electric EGR Transducer contains an electrically operated solenoid and a back-pressure controlled vacuum transducer Fig. 27. The PCM operates the solenoid based on inputs from the multi-port fuel injection system. The solenoid/transducer and EGR valve are serviced as an assembly. When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to the transducer when the PCM de-energizes the solenoid. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the vacuum transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of the vacuum signal applied to the EGR valve. Varying the strength of the vacuum signal changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. The solenoid/transducer and EGR valve mount to the rear of the cylinder head Fig. 28 or 29. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations > Page 3087 EGR Backpressure Transducer: Testing and Inspection The first part of this test will determine if the transducer diaphragm at the back-pressure has ruptured or is leaking. The second part of the test will determine if engine vacuum (full manifold) is flowing from the inlet to the outlet side of the transducer. 1. Electrical operation of the solenoid should be checked with the DRB scan tool before proceeding with the vacuum test. 2. Disconnect the rubber back-pressure hose from the fitting at the bottom of the transducer. 3. Connect a hand-held vacuum pump to this fitting. 4. Apply 10 inches of vacuum to this fitting. 5. If vacuum falls off, the transducer diaphragm is leaking. 6. Replace the transducer and EGR valve assembly. Connect the rubber hose to the transducer and proceed to next step for further testing. 7. Remove the rubber hose at the vacuum inlet fitting on the EGR solenoid. 8. Connect a vacuum gauge to this disconnected hose. 9. Start the engine and bring to operating temperature. Hold engine speed at approximately 1,500 rpm. 10. Check for steady engine vacuum (full manifold) at this hose. If engine vacuum is not present, check vacuum line to engine and repair as necessary before proceeding to next step. 11. Connect the hose to the vacuum inlet fitting on the solenoid. 12. Disconnect the rubber hose at the vacuum outlet hose on the transducer. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical connector from the solenoid. This will simulate an open circuit. 15. Start the engine and bring to operating temperature. - Hold the engine speed at approximately 2,000 rpm while checking for vacuum (full manifold) at this fitting. - As temporary back-pressure is built, full manifold vacuum should be observed at the outlet fitting. - Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low. This low reading is normal. - At idle speed, the gauge reading will be erratic. This is also normal. 16. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the transducer and EGR valve assembly. Refer to EGR Valve Replacement. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Service and Repair > EGR Valve and Electric EGR Transducer Replacement EGR Backpressure Transducer: Service and Repair EGR Valve and Electric EGR Transducer Replacement Fig. 2 EGR Control Valve Fig. 3 EGR Valve NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and electrical transducer are calibrated together. NOTE: The EGR valve attaches to the front exhaust manifold. The transducer/solenoid attach to the front cylinder head (Fig. 3). REMOVAL 1. Disconnect vacuum supply and outlet hose from solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove back-pressure hose from transducer. 4. Pull transducer/solenoid up off of bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Service and Repair > EGR Valve and Electric EGR Transducer Replacement > Page 3090 Fig. 5 TCM Removal Fig. 6 EGR Removal; 5. Remove screws holding Transmission Control Module (TCM) to bracket (Fig. 5). Swing TCM up to allow access to EGR screws (Fig. 6). 6. Remove screws holding EGR tube. 7. Remove EGR valve mounting screws. Remove EGR valve and transducer. 8. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lbs) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lbs) torque. 5. Clip solenoid to bracket. 6. Connect back-pressure hose to EGR valve and transducer. 7. Connect vacuum supply and outlet hoses to solenoid. 8. Attach electrical connector to solenoid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Service and Repair > EGR Valve and Electric EGR Transducer Replacement > Page 3091 EGR Backpressure Transducer: Service and Repair EGR Tube Fig. 8 EGR Tube At Intake Manifold NOTE: The EGR tube attaches to the intake manifold plenum behind the throttle body and to the EGR valve. REMOVAL 1. Remove screws attaching EGR tube to intake manifold (Fig. 8). Fig. 9 EGR Tube At EGR Valve 2. Remove EGR tube to EGR valve screws (Fig. 9). 3. Remove EGR tube. Clean gasket surface on the EGR valve. Wipe clean the grommet on the intake manifold. NOTE: Use new gaskets on both ends of the EGR tube. INSTALLATION 1. Loosely install the EGR tube and fasteners. 2. Tighten the EGR tube to intake manifold plenum screws to 11 Nm (95 in lb) torque. 3. Tighten the EGR tube to EGR valve screws to 11 Nm (95 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations Fig. 29 EGR Control Valve Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions EGR Control Solenoid: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3097 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3098 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3099 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3100 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3101 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 EGR Control Solenoid: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3112 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3113 EGR Solenoid Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 3114 EGR Solenoid Circuit Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Page 3115 EGR Control Solenoid: Description and Operation Fig. 27 Electronic EGR Transducer Fig. 29 EGR Control Valve OPERATION The Electric EGR Transducer contains an electrically operated solenoid and a back-pressure controlled vacuum transducer Fig. 27. The PCM operates the solenoid based on inputs from the multi-port fuel injection system. The solenoid/transducer and EGR valve are serviced as an assembly. When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to the transducer when the PCM de-energizes the solenoid. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the vacuum transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of the vacuum signal applied to the EGR valve. Varying the strength of the vacuum signal changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. The solenoid/transducer and EGR valve mount to the rear of the cylinder head Fig. 28 or 29. CIRCUIT OPERATION Circuit A142 supplies voltage to the EET solenoid. The Powertrain Control Module (PCM) controls the ground path for the solenoid on circuit K35 and connects to cavity 40 of the PCM connector. Circuit A142 is spliced and connects with the fuel injectors, generator, and the Automatic Shut-Down (ASD) relay. This circuit is HOT when the ASD relay is energized. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Page 3116 EGR Control Solenoid: Testing and Inspection Electrical operation of the valve control should be checked with a scan tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Page 3117 EGR Control Solenoid: Service and Repair Fig. 2 EGR Control Valve Fig. 3 EGR Valve NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and electrical transducer are calibrated together. NOTE: The EGR valve attaches to the front exhaust manifold. The transducer/solenoid attach to the front cylinder head (Fig. 3). REMOVAL 1. Disconnect vacuum supply and outlet hose from solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove back-pressure hose from transducer. 4. Pull transducer/solenoid up off of bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Diagrams > Page 3118 Fig. 5 TCM Removal Fig. 6 EGR Removal; 5. Remove screws holding Transmission Control Module (TCM) to bracket (Fig. 5). Swing TCM up to allow access to EGR screws (Fig. 6). 6. Remove screws holding EGR tube. 7. Remove EGR valve mounting screws. Remove EGR valve and transducer. 8. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lbs) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lbs) torque. 5. Clip solenoid to bracket. 6. Connect back-pressure hose to EGR valve and transducer. 7. Connect vacuum supply and outlet hoses to solenoid. 8. Attach electrical connector to solenoid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation EGR Electronic Vacuum Regulator Solenoid: Description and Operation Circuit A142 supplies voltage to the EET solenoid. The Powertrain Control Module (PCM) controls the ground path for the solenoid on circuit K35 and connects to cavity 40 of the PCM connector. Circuit A142 is spliced and connects with the fuel injectors, generator, and the Automatic Shut-Down (ASD) relay. This circuit is HOT when the ASD relay is energized. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR tube to intake torque ................................................................................................................... ........................................................ 11 Nm (95 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3125 EGR Tube: Service and Repair Fig. 8 EGR Tube At Intake Manifold NOTE: The EGR tube attaches to the intake manifold plenum behind the throttle body and to the EGR valve. REMOVAL 1. Remove screws attaching EGR tube to intake manifold (Fig. 8). Fig. 9 EGR Tube At EGR Valve 2. Remove EGR tube to EGR valve screws (Fig. 9). 3. Remove EGR tube. Clean gasket surface on the EGR valve. Wipe clean the grommet on the intake manifold. NOTE: Use new gaskets on both ends of the EGR tube. INSTALLATION 1. Loosely install the EGR tube and fasteners. 2. Tighten the EGR tube to intake manifold plenum screws to 11 Nm (95 in lb) torque. 3. Tighten the EGR tube to EGR valve screws to 11 Nm (95 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine - Rough Idle, Hard Start, or Start & Stall EGR Valve: Technical Service Bulletins Engine - Rough Idle, Hard Start, or Start & Stall NUMBER: 18-020-01 GROUP: Vehicle Performance DATE: Aug. 17, 2001 SUBJECT: Rough Idle, Hard Start, Start & Stall OVERVIEW: This bulletin involves installing a revised EGR valve. MODELS: 1995 - 2000 (JA) Breeze/Cirrus/Stratus 1996 - 2000 (JX) Sebring Convertible NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.5L ENGINE. SYMPTOM/CONDITION: Vehicle may intermittently exhibit any of the following conditions: ^ Rough engine idle. ^ Hard start or long crank after hot soak. ^ Start and stall when started with cold engine ^ Diagnostic Trouble Code (DTC) P0300, Multiple Cylinder Mis-fire. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition(s) can be duplicated or is described by the customer, it may be caused by the EGR valve being stuck partially open. To confirm whether or not the valve is stuck partially open: 1. If the condition(s) can be duplicated, then block off the EGR passageway to the intake manifold. If the condition(s) disappear, but will reappear when the EGR passageway is re-opened, perform the Repair Procedure. 2. If the condition(s) cannot be duplicated, but are described by the customer, perform the Repair procedure. PARTS REQUIRED: REPAIR PROCEDURE: Install the revised EGR valve as described in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Engine - Rough Idle, Hard Start, or Start & Stall > Page 3130 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 3131 EGR Valve: Description and Operation PURPOSE To assist in the control of oxides of nitrogen (NOx) in engine exhaust, all engines are equipped with an exhaust gas recirculation system. The use of exhaust gas to dilute incoming air/fuel mixtures lowers peak flame temperatures during combustion, thus limiting the formation of NOx. OPERATION Exhaust gases are taken from opening in the exhaust manifold passage to the intake manifold. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 3132 EGR Valve: Testing and Inspection If the engine will not idle, dies out at idle, or idle is rough or slow, the poppet valve at the base of the EGR valve may be leaking in the closed position. The diaphragm within the EGR valve may also be ruptured. 1. The engine should be off for the following test. 2. Disconnect the rubber hose from the fitting at the top, vacuum motor, of the EGR valve. a. Connect a hand-held vacuum pump to this fitting. b. Apply 15 inches of vacuum to the pump. c. Observe the gauge reading on the pump. d. If vacuum falls off, the diaphragm in the EGR valve is ruptured. e. Replace the EGR valve. f. Proceed to next step. 3. A small fitting (back pressure fitting) is located at the base of the EGR valve. A rubber hose connects it to the back-pressure fitting on the EGR valve control. Disconnect this rubber hose at the EGR valve. 4. Remove air inlet tube from throttle body. 5. Using compressed air and an air nozzle with a rubber tip, apply approximately 50 psi of regulated shop air to the metal back pressure fitting on the EGR valve. 6. By hand, open the throttle to the wide open position. Air should not be heard coming from the intake manifold. 7. If air can be heard coming from the intake manifold, the poppet valve is leaking at the bottom of the EGR valve. Replace the EGR valve. Do not attempt to clean the old EGR valve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation Fig. 8 PCV Valve Intake manifold vacuum removes crankcase vapors and piston blow-by from the separator. Emissions pass through the PCV valve into the intake manifold plenum. The vapors become part of the calibrated air-fuel mixture, are burned and then expelled with the exhaust gases. The air cleaner supplies make up air when the engine does not have enough vapor or blow-by gases. PCV Valve The Positive Crankcase Ventilation (PCV) valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 9 Engine Off Or Engine Backfire--No Vapor Flow When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve (Fig. 9). Fig. 10 High Intake Manifold Vacuum--Minimal Vapor Flow When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve (Fig. 10). In this position there is minimal vapor flow through the valve. Fig. 11 Moderate Intake Manifold Vacuum--Maximum Vapor Flow Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3136 During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve (Fig. 11). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3137 Positive Crankcase Ventilation: Testing and Inspection WARNING: Apply parking brake and/or block wheels before performing any test or adjustment with the engine operating. 1. With engine idling, remove the vapor hose from the PCV valve. If the valve is not plugged, a hissing noise will be heard as air passes through the valve. A strong vacuum should also be felt when a finger is placed over the valve inlet. 2. Install hose on PCV valve. Remove the make-up air hose from the air plenum at the rear of the engine. Hold a piece of stiff paper (parts tag) loosely over the end of the make-up air hose. 3. After allowing approximately one minute for crankcase pressure to reduce, the paper should draw up against the hose with noticeable force. If the engine does not draw the paper against the grommet after installing a new valve, replace the PCV valve hose. 4. Turn the engine off. Remove the PCV valve from intake manifold. The valve should rattle when shaken. NOTE: Replace the PCV valve and retest the system if it does not operate as described in the preceding tests. Do not attempt to clean the old PCV valve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Adapter Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3146 Fuel Pressure Release: Service and Repair Fig. 2 Releasing Fuel Pressure Fig. 1 Fuel Pressure Test Port--Typical CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock. 1. Disconnect the fuel rail electrical harness from the engine harness. Refer to Diagrams/Electrical. 2. Connect one end of a jumper wire to the A142 circuit terminal of the fuel rail harness connector. 3. Connect the other end of the jumper wire to a 12 volt power source. 4. Connect one end of a jumper wire to a good ground source. 5. Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector. Repeat procedure for 2 to 3 injectors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 miles ................................................................................ .............................................................................................. 450 - 1,100 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 500 - 1,100 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3150 Idle Speed: Testing and Inspection Fig. 35 Purge Hose 1. Turn ignition key to Off. 2. Disconnect the PCV valve hose from the intake manifold nipple. Cap the PCV vacuum nipple. 3. Disconnect purge hose from the nipple on the throttle body Fig. 35. Fig. 37 Orifice6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) to the purge nipple on the throttle body Fig. 37. 5. Ensure that all accessories are off. 6. Connect the DRB Scan Tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB Scan Tool, access Minimum Airflow Idle Speed. 9. The following will then occur: - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB Scan Tool displays engine RPM 10. If idle RPM is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. - Below 1,000 miles ............................................................................................................................. ........................................... 450 - 1,100 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 500 - 1,100 rpm 11. If idle RPM is above specifications, use the DRB Scan Tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves. DO NOT let Mopar (TM) Parts Cleaner come in contact with eyes or skin. DO NOT ingest the cleaner. Wash thoroughly after using cleaner. a. Remove the throttle body from engine. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar (TM) Parts Cleaner. Only use Mopar (TM) Parts Cleaner to clean the throttle body. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3151 c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB Scan Tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator pedal to dash nuts torque ........................................................................................................................................................ 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3155 Accelerator Pedal: Service and Repair Fig. 1 Accelerator Pedal And Throttle Cable CAUTION: When servicing the accelerator pedal or throttle cable, do not damage or kink the control cable core wire. REMOVAL 1. Remove the throttle cable from the throttle body cam. 2. Reach behind the top of the pedal shaft and push the retainer toward rear of vehicle Fig. 1. It may be necessary to squeeze retainer ears together on dash side of pedal shaft. 3. Lift cable up through slot in top of pedal shaft. 4. Remove nuts from accelerator pedal assembly studs Fig. 1. Remove assembly from vehicle. INSTALLATION 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 Nm (105 in. lbs.) torque. 2. Place cable through slot in top of pedal shaft. 3. Step on pedal and retainer will snap into place. 4. Hold the throttle body lever in the wide open position and install the throttle cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Air Cleaner Housing And Element REMOVAL 1. Unfasten clasps on rear of air cleaner housing cover. Lift cover off air cleaner housing. Air Cleaner Housing And Element 2. Remove filter element. 3. If necessary clean the inside of the air cleaner housing. INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps in place. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels Fuel: Technical Service Bulletins Engine - High Driveability Index Fuels NO: 14-08-97 GROUP: Fuel DATE: Nov. 21, 1997 SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel MODELS: 1996 - 1998 (AB) Ram Van/Wagon 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (PL) Neon 1997 (PR) Prowler 1996 - 1998 (SR) Viper Roadster/Coupe 1997 - 1998 (TJ) Wrangler 1996 - 1998 (XJ) Cherokee 1995 - 1998 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F). DISCUSSION: Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems. For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance. The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular. Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane. Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock. Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels > Page 3164 contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline. The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction. If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3165 Fuel: Specifications Fuel Grade Fuel Grade Unleaded - Min Octane 87 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications Fuel Filler Cap: Specifications Filler Cap Vent Limits Pressure Release .............................................................................................................................................................. 13.45 kPa (1.58 to 1.95 psi) Vacuum Release ...................................................................................................................................................... 0.97 to 2.0 kPa (0.14 to 0.29 psi) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications > Page 3169 Fuel Filler Cap: Description and Operation Fig. 4 Pressure Vacuum Filler Cap WARNING: Remove fuel filler tube cap to relieve tank pressure before removing or repairing fuel system components. PURPOSE A pressure-vacuum relief cap seals the fuel tank (Fig. 4). The loss of any fuel or vapor out of the filler tube neck is prevented by the use of a safety filler cap. OPERATION Tightening the cap on the fuel filler tube forms a seal between them. The relief valves in the cap are a safety feature. They prevent possible excessive pressure or vacuum in the tank. Excessive fuel tank pressure could be caused by a malfunction in the system or damage to the vent lines. The seal between the cap and filler tube breaks when the cap is removed. Breaking the seal relieves fuel tank pressure. Pressure Release The cap releases only under significant pressure 10.9 to 13.45 kPa (1.58 to 1.95 psi). Vacuum Release The vacuum release for all gas caps is between 0.97 and 2.0 kPa (0.14 and 0.29 psi). Replacement If the filler cap needs replacement, only use an original equipment or equivalent unit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3174 Fuel Pressure Release: Service and Repair Fig. 2 Releasing Fuel Pressure Fig. 1 Fuel Pressure Test Port--Typical CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock. 1. Disconnect the fuel rail electrical harness from the engine harness. Refer to Diagrams/Electrical. 2. Connect one end of a jumper wire to the A142 circuit terminal of the fuel rail harness connector. 3. Connect the other end of the jumper wire to a 12 volt power source. 4. Connect one end of a jumper wire to a good ground source. 5. Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector. Repeat procedure for 2 to 3 injectors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Injector Circuit Test Revisions Fuel Injector: Technical Service Bulletins Fuel System - Injector Circuit Test Revisions NUMBER: 26-05-98E GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L Passenger Car Powertrain Diagnostic Manual Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the injector circuit test Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Injector Circuit Test Revisions > Page 3179 153 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Injector Resistance .............................................................................................................................. .......................................... 12 ohms at 20 ° C (68 ° F) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3182 Fuel Injector: Pressure, Vacuum and Temperature Specifications Information not supplied by the manufacturer. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3183 Fuel Injection System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3184 Injector #1 Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injectors Description Fuel Injector: Description and Operation Fuel Injectors Description Fuel Injector OPERATION All these engines use electrically operated top feed fuel injectors Fig. 30. The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors. The PCM controls the ground path for each injector in sequence. By switching the ground paths on and off, the PCM fine-tunes injector pulse width. Injector pulse width refers to the amount of time an injector operates. The PCM determines injector synchronization from the camshaft position sensor and crankshaft position sensor inputs. The PCM grounds the ASD and fuel pump relays after receiving the camshaft position sensor and crankshaft position sensor inputs. The PCM energizes the injectors in a sequential order during all engine operating conditions except start-up. For the first injector pulse width during start-up, all injectors are energized at the same time. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Injector Resistance The injectors are 12 ohm electrical solenoids. CIRCUIT OPERATION Circuit A14 is connected to the BUS bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut-Down (ASD) relay connects circuit A14 and A142. A 20 amp fuse, in cavity 5 of the PDC, protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM. Circuit A142 supplies voltage for the fuel injectors. The PCM controls the ground circuit of each injector, as follows: Circuit K11 is the ground circuit for Injector #1. Circuit K11 connects to cavity 13 of the PCM. - Circuit K12 is the ground circuit for Injector #2. Circuit K12 connects to cavity 17 of the PCM. - Circuit K13 is the ground circuit for Injector #3. Circuit K13 connects to cavity 7 of the PCM. - Circuit K14 is the ground circuit for Injector #4. Circuit K14 connects to cavity 16 of the PCM. - Circuit K38 is the ground circuit for Injector #5. Circuit K38 connects to cavity 15 of the PCM. - Circuit K58 is the ground circuit for Injector #6. Circuit K58 connects to cavity 14 of the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injectors Description > Page 3187 Fuel Injector: Description and Operation Injector Control Circuit NAME OF CODE: Injector Control Circuit WHEN MONITORED: With battery voltage greater than 12 volts, the auto shutdown (ASD) relay energized, injector pulse width less than 10 milliseconds, and engine speed less than 3000 RPM. SET CONDITION: This trouble code takes 0.64 to 10.0 seconds to set when no inductive kick is sensed 0.18 milliseconds after injector turns off, and with no other injectors on. THEORY OF OPERATION: Fuel injectors are high-impedance solenoids controlled by the Powertrain Control Module (PCM). Battery voltage is supplied by the ASD relay. The injector ON time (pulse width) is controlled by the amount of time the PCM grounds the injector control circuit. By varying this time, more or less fuel is allowed to flow through the injector. POSSIBLE CAUSES: - Open or shorted injector driver circuit - Open injector - Open ASD supply at injector - Failed driver in PCM Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information Fuel Injector: Testing and Inspection Helpful Information - Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. - The injectors operate in sequence. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 3190 Fuel Injector: Testing and Inspection Resistance Test Related Images Check resistance between the injector terminals. Resistance should be between 10 and 16 ohms. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 3191 Fuel Injector Diagnosis Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3192 Fuel Injector: Service and Repair Fig. 18 Fuel Injector Clip FUEL INJECTORS 1. Remove fuel rail. 2. Remove fuel injector clip Fig. 18. 3. Pull injector out of fuel rail. 4. Replace fuel injector 0-rings. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation Fig. 5 Plastic Quick-Connect Fittings FUEL LINES AND QUICK CONNECT FITTINGS Fuel Lines Fuel line clamps are not used on any fuel system component. If there is a fitting or line that needs repair it must be replaced. DO NOT use rubber hose and clamps to repair a fuel line. Inspect all lines and quick connect fittings for leaks. Replace lines that rub against other vehicle components or show sign of wear. Ensure all lines are secured in their proper holders. Quick - Connect Fittings Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable 0-ring seals Fig. 5. CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quick-connect fittings or fuel tubes. Replace the complete fuel tube/quick-connect fitting assembly. The quick-connect fitting consists of the 0-rings, retainer and casing Fig. 5. When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the 0-rings seal the tube. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3196 Fuel Line Coupler: Service and Repair Fig. 5 Plastic Quick-Connect Fittings FUEL LINES AND QUICK CONNECT FITTINGS Fuel Lines Fuel line clamps are not used on any fuel system component. If there is a fitting or line that needs repair it must be replaced. DO NOT use rubber hose and clamps to repair a fuel line. Inspect all lines and quick connect fittings for leaks. Replace lines that rub against other vehicle components or show sign of wear. Ensure all lines are secured in their proper holders. Quick - Connect Fittings Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable 0-ring seals Fig. 5. CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quick-connect fittings or fuel tubes. Replace the complete fuel tube/quick-connect fitting assembly. The quick-connect fitting consists of the 0-rings, retainer and casing Fig. 5. When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the 0-rings seal the tube. REMOVAL When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: Release fuel system pressure before disconnecting quick-connect fittings. Refer to the fuel pressure release procedure. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Perform Fuel Pressure Release Procedure. Refer to Fuel Pressure Release Procedure. 3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube. Fig. 6 Plastic Quick-Connect Fitting/Fuel Tube Connection INSTALLATION Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3197 1. Using a clean lint free cloth, clean fuel tube nipple and retainer. 2. Prior to connecting fitting to the fuel tube, coat fuel tube nipple with clean 30 weight engine oil. CAUTION: Never install a quick-connect fitting without retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure retainer locks securely into quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. 3. Push quick-connect fitting over fuel tube until retainer seats and a click is heard. NOTE: The quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed Fig. 6. - Do not rely upon the audible click to confirm a secure connection. 4. Ensure locking ears on retainer and the shoulder (stop bead) on the fuel tube are completely visible in the quick-connect fitting windows. - Do not rely upon the audible click to confirm a secure connection. - Always pull on the line and fitting to ensure that retainer is seated. 5. Verify connection by pulling on the lines. - If fitting locks in place, the connection is secure. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position. 6. Use DRB Scan Tool-ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Fuel pump activated -- ......................................................................................................................... .......................................... 338 kPa (47-51 psi) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3201 Fuel Pressure Regulator: Description and Operation Fig. 20 Fuel Pressure Regulator The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at approximately 338 kPa (49 psi). The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down on the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of fuel pressure required to open the return port. NOTE: The fuel pressure regulator is NOT controlled by the PCM or engine vacuum. The fuel pressure regulator is part of the fuel pump module Fig. 20. Remove the fuel pump module from the fuel tank for access to the fuel pressure regulator. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3202 Fuel Pressure Regulator: Service and Repair Fig. 20 Fuel Pressure Regulator The fuel pressure regulator is part of the fuel pump module Fig. 20. Remove the fuel pump module from the fuel tank for access to the fuel pressure regulator. Fig. 20 Fuel Pressure Regulator NOTE: Remove the fuel pump module from the fuel tank for access to the fuel pressure regulator. REMOVAL 1. Spread tangs on pressure regulator retainer Fig. 20. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3203 Fig. 21 Fuel Pressure Regulator Removal 2. Pry fuel pressure regulator out of housing Fig. 21. 3. Ensure both upper and lower 0-rings are removed from regulator housing and discarded. Fig. 22 Fuel Pressure Regulator O-Rings INSTALLATION 1. Lightly lubricate the 0-rings with engine oil and place them into opening in regulator housing Fig. 22. 2. Push and rotate regulator into regulator housing. 3. Install new regulator retainer bracket making sure all 4 locking tabs snap into place. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Adapter Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Adapter Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Relay Connector Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 3217 Fuel Pump Relay: Diagrams Power Distribution Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 3218 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 3219 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 3220 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 3221 Fuel Pump Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) FUEL PUMP RELAY - PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. Power for the solenoid is supplied through a 10A fuse in the Junction Block. The contacts are supplied power through a 20A fuse in the PDC. Refer to Diagrams/Electrical for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. The fuel pump relay is located in the PDC Fig. 25. The inside top of the PDC cover has a label showing relay and fuse location. Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 3222 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 3223 Fuel Pump Relay: Testing and Inspection Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Bolts ..................................................................................................................................... ...................................................... 12 Nm (106 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3227 Fuel Rail: Service and Repair Fig. 9 Intake Manifold Plenum Sensors And Left Plenum Support Bolt REMOVAL 1. Disconnect negative cable from auxiliary jumper terminal. WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing the vehicle. 2. Release fuel system pressure. See: Service and Repair WARNING: Wrap shop towels around hose to catch any gasoline spillage. 3. Disconnect fuel supply tube from rail. See: Service and Repair 4. Unplug connectors from MAP and intake air temperature sensors Fig. 9. 5. Remove plenum support bracket bolt located rearward of MAP sensor Fig. 9. Fig. 3 Air Inlet Resonator 6. Remove bolt holding air inlet resonator to intake plenum Fig. 3. 7. Loosen throttle body air inlet hose clamp. 8. Release snaps holding air cleaner housing cover to housing. 9. Remove air cleaner cover and inlet hoses from engine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3228 Fig. 10 Throttle Position Sensor Fig. 11 Air Control Motor 10. Unplug TPS and idle air control motor connectors Fig. 10 and 11. 11. Pry retainer tab back on throttle cable and slide cable out of bracket Fig. 12. Fig. 12 Throttle Cable Attachment 12. Slide Speed control cable out of bracket, if equipped Fig. 12. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3229 Fig. 13 EGR Tube And Right Plenum Support Bolt 13. Remove EGR tube from intake plenum Fig. 13. 14. Remove plenum support bracket bolt located rearward of EGR tube Fig. 13. 15. Remove 7 bolts holding upper intake plenum and remove plenum. 16. Disconnect electrical connectors from fuel injectors. Fig. 13 EGR Tube And Right Plenum Support Bolt 17. Remove 4 bolts holding fuel rail Fig. 14. Fig. 15 Fuel Rail Spacers 18. Lift fuel rail off engine. There are spacers under each fuel rail bolt Fig. 15. INSTALLATION 1. Apply a light coating of clean engine oil to the 0-ring on the nozzle end of each injector. CAUTION: Make sure spacers are located under each fuel rail mounting position. 2. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 Nm (8 ft. lbs.). 3. Attach electrical connectors to fuel injectors. 4. Connect fuel supply tube to fuel rail. See: Service and Repair 5. Install new gasket and position upper intake plenum. Tighten plenum bolts to 18 Nm (13 ft. lbs.) torque. 6. Install bolts at plenum support brackets. Tighten bolts to 18 Nm (13 ft. lbs.). 7. Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 in. lbs.) torque. 8. Install throttle cables. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3230 9. Attach electrical connectors to sensors. 10. Tighten air inlet tube clamps to 3 Nm ± 1 (25 ± 5 in. lbs. ) torque. 11. Connect negative terminal to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair Fig. 4 Fuel Filler Neck Removal/Installation 1. Loosen fuel filler tube cap. 2. Remove fuel filler neck screws (Fig 4). 3. Disconnect fuel filler tube from filler neck. 4. Remove filler neck. 5. Reverse for installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications SENDING UNIT RESISTANCE -- OHMS Full (142.2 ± 4.0 mm) Nominal ............................................................................................................................................... ............................................................... 70 - Upper Limit ........................................................................................................................................ ................................................................ 90 - Lower Limit ........................................................................................................................................ ............................................................... 50 3/4 Tank (97.2 mm) Nominal ............................................................................................................................................... ............................................................. 340 - Upper Limit ........................................................................................................................................ .............................................................. 370 - Lower Limit ........................................................................................................................................ ............................................................. 310 1/2 Tank (66.1 mm) Nominal ............................................................................................................................................... ............................................................. 550 - Upper Limit ........................................................................................................................................ .............................................................. 580 - Lower Limit ........................................................................................................................................ ............................................................. 520 1/4 Tank (34.8 mm) Nominal ............................................................................................................................................... ............................................................. 760 - Upper Limit ........................................................................................................................................ .............................................................. 790 - Lower Limit ........................................................................................................................................ ............................................................. 730 Empty (0.5 ± 4.0 mm) Nominal ............................................................................................................................................... ........................................................... 1050 - Upper Limit ........................................................................................................................................ ............................................................ 1080 - Lower Limit ........................................................................................................................................ ........................................................... 1020 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 3238 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Drain Plug > Component Information > Specifications Fuel Tank Drain Plug: Specifications Fuel Tank Drain Plug ........................................................................................................................... ...................................................... 3.6 Nm (32 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Drain Plug > Component Information > Specifications > Page 3242 Fig. 1 Fuel Tank Drain Plug Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications Fuel Tank Unit: Specifications Fuel Pump Module Locknut ................................................................................................................. ........................................................ 61 Nm (45 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3246 Fuel Tank Unit: Description and Operation Fig. 9 Fuel Pump Module FUEL PUMP MODULE The fuel pump module is installed in the top of the fuel tank Fig. 9. The fuel pump module contains the following: Electric fuel pump. - Fuel pump reservoir - Inlet strainer. - Fuel pressure regulator. - Fuel gauge sending unit - Fuel supply and return line connections The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module. ELECTRIC FUEL PUMP The electric fuel pump is located in and is part of the fuel pump module. It is a positive displacement, gerotor, immersible pump with a permanent magnet electric motor. The fuel pump module is suspended in fuel in the fuel tank. The pump draws fuel through a strainer and pushes it through the motor to the outlet. The pump contains two valves. One valve relieves internal fuel pump pressure and regulates maximum pump output. - The second valve, in the pump outlet, maintains pump pressure during engine off conditions. The fuel pump relay provides voltage to the fuel pump. The fuel pump has a maximum deadhead pressure output of approximately 635 kPa (95 psi). The regulator adjusts fuel system pressure to approximately 331 kPa (49 psi). Fuel Pump Electrical Control Voltage to operate the electric fuel pump is supplied through the fuel pump relay. Fuel Pump Replacement The fuel pump is not serviceable. If the fuel pump or electrical wiring harness needs replacement, the complete fuel pump module must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3247 Fuel Tank Unit: Service and Repair Fig. 9 Fuel Pump Module FUEL PUMP MODULE The fuel pump module is installed in the top of the fuel tank Fig. 9. The fuel pump module contains the following: Electric fuel pump. - Fuel pump reservoir - Inlet strainer. - Fuel pressure regulator. - Fuel gauge sending unit - Fuel supply and return line connections The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module. Fig. 10 Fuel Pump Module Locknut ELECTRICAL PUMP REPLACEMENT The electric fuel pump is not serviceable. If the fuel pump needs replacement, the complete fuel pump module must be replaced. Perform the Fuel System Pressure Release procedure before servicing the fuel pump. See: Fuel Filter/Fuel Pressure Release/Service and Repair WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing the vehicle. FUEL PUMP MODULE REMOVAL 1. Remove fuel filler cap and perform Fuel System Pressure Release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect negative cable from auxiliary jumper terminal. 3. Remove fuel tank. 4. Disconnect fuel filter lines from fuel pump module. 5. Clean top of tank to remove loose dirt and debris. 6. Using Special Tool #6856 Fuel Pump Module Ring Spanner, remove locknut to release pump module Fig. 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3248 WARNING: The fuel reservoir or the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Fig. 11 Fuel Pump Module Removal 7. Remove fuel pump module and 0-ring from tank Fig. 11. Discard 0-ring. FUEL PUMP MODULE INSTALLATION 1. Wipe seal area of tank clean. Place a new 0-ring on the ledge between the tank threads and the pump module opening. 2. Position fuel pump module in tank. - Make sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank. CAUTION: Over tightening the pump lock ring may result in a leak. 3. While holding the pump module in position, install locknut. Tighten locknut to 61 Nm (45 ft lb) torque using special tool #6856. 4. Install fuel tank and fuel filter. 5. Fill fuel tank with clean fuel. Check for leaks. 6. Install negative cable to auxiliary jumper terminal. Fig. 12 Inlet Strainer Removal FUEL PUMP INLET STRAINER SERVICE - REMOVAL 1. Remove fuel pump module. 2. Using a thin straight blade screwdriver, carefully pry back the locking tabs on fuel pump reservoir and remove the strainer Fig. 12. 3. Remove strainer 0-ring from the fuel pump reservoir body. 4. Remove any contaminants by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer 0-ring with clean motor oil. 2. Insert strainer 0-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3249 Fig. 14 Fuel Pump/Level Sensor Electrical Connector FUEL LEVEL SENSOR The fuel level sensor attaches to the side of the fuel pump module. Remove the fuel pump module to replace the fuel level sensor. Fig. 14 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module to gain access to this sensor. REMOVAL 1. Depress retaining tab and remove fuel pump/level sensor connector from bottom of fuel pump module electrical connector Fig. 14. Fig. 15 Terminal Removal Tool 2. Using Special Tool #C-4334 terminal remover or equivalent, remove terminals from level sensor connector Fig. 15. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3250 Fig. 16 Loosening Level Sensor 3. Insert a screwdriver between the fuel pump module and the top of the level sensor housing Fig. 16. Push level sensor down slightly. 4. Slide level sensor wires through opening fuel pump module. 5. Slide level sensor out of installation channel in module. Fig. 17 Groove In Back Side Of Level Sensor INSTALLATION 1. Insert level sensor wires into bottom of opening in module. 2. Wrap wires into groove in back of level sensor Fig. 17. Fig. 18 Installation Channel 3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place Fig. 18. Ensure tab at bottom of sensor locks in place. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3251 Fig. 19 Fuel Pump/Level Sensor Electrical Connector 4. Install level sensor wires in connector. - Push the wires up through the connector and then pull them down until they lock in place. - Ensure signal and ground wires are installed in the correct position Fig. 19. 5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module electrical connector. 7. Install fuel pump module. Fig. 20 Fuel Pressure Regulator FUEL PRESSURE REGULATOR The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at approximately 338 kPa (49 psi). The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down on the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of fuel pressure required to open the return port. The fuel pressure regulator is part of the fuel pump module Fig. 20. Remove the fuel pump module from the fuel tank for access to the fuel pressure regulator. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3252 NOTE: Remove the fuel pump module from the fuel tank for access to the fuel pressure regulator. REMOVAL 1. Spread tangs on pressure regulator retainer Fig. 20. Fig. 21 Fuel Pressure Regulator Removal 2. Pry fuel pressure regulator out of housing Fig. 21. 3. Ensure both upper and lower 0-rings are removed from regulator housing and discarded. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3253 Fig. 22 Fuel Pressure Regulator O-Rings INSTALLATION 1. Lightly lubricate the 0-rings with engine oil and place them into opening in regulator housing Fig. 22. 2. Push regulator into opening in pump module. 3. Fold tangs on regulator retainer over tabs on housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control Motor screws .............................................................................................................. ......................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3257 Idle Speed/Throttle Actuator - Electronic: Locations Idle Air Control Motor Fig. 32 Idle Air Control Motor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3258 Idle Air Control Motor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3259 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig. 32 Idle Air Control Motor PURPOSE The Idle Air Control (IAC) motor is mounted on the throttle body. The PCM operates the idle air control motor Fig. 31. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load, coolant temperature or barometric pressure changes. OPERATION The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control motor pintle protrudes into the air bypass passage and regulates air flow through it. The PCM adjusts engine idle speed by moving the IAC motor pintle in and out of the bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning and power steering). CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the idle air control motor through 4 circuits - K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector Circuit K39 connects to cavity 57 of the PCM connector - Circuit K40 connects to cavity 48 of the PCM connector - Circuit K59 connects to cavity 58 of the PCM connector - Circuit K60 connects to cavity 49 of the PCM connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3260 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 26 Throttle Position Sensor And Idle Air Control Motor The idle air control motor attaches to the side of the throttle body Fig. 26. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Remove throttle body. 3. Disconnect electrical connector from idle air control motor and throttle position sensor. 4. Remove idle air control motor mounting screws. 5. Remove idle air control motor. Ensure 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB AIS Motor Open/Close Test to retract the pintle (battery must be connected.) 2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install throttle body. 5. Attach electrical connectors to idle air control motor and throttle position sensor. 6. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3264 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3265 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3266 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3267 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3268 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, generator field, electronic ignition coil and the heating elements in the oxygen sensors. Refer to Diagrams/Electrical for circuit information. The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. OPERATION The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. When the ignition switch is in On or Start, the PCM momentarily turns on the ASD relay. The PCM also monitors the ASD relay output voltage. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. While the relay is on the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the PDC Fig. 25. The inside top of the PDC cover has label showing relay and fuse identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3269 Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Power for the coil and contact side of the relay is provided by circuit A14. This circuit is HOT at all times and protected by a 20 amp fuse located in cavity 5 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the relay on circuit K51. This circuit connects to cavity 67 of the PCM connector. When the relay is energized, the contacts internal to the relay close connecting circuits A14 and A142. The A142 circuit is spliced and provides power to the fuel injectors, generator, electronic EGR transducer solenoid, and the ignition coil. The A142 circuit is also spliced and connects to the PCM connector, cavity 6. This input is used for ASD sense by the PCM. HELPFUL INFORMATION Check the 20 amp fuse located in cavity 5 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in cavity 5 of the PDC Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 3272 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD Relay Test Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 3273 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 1 ASD And Fuel Pump Relay Terminals OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Electrical Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 3280 Fuel Pump Relay: Diagrams Power Distribution Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 3281 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 3282 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Relay Connector > Page 3283 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3284 Fuel Pump Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) FUEL PUMP RELAY - PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. Power for the solenoid is supplied through a 10A fuse in the Junction Block. The contacts are supplied power through a 20A fuse in the PDC. Refer to Diagrams/Electrical for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. The fuel pump relay is located in the PDC Fig. 25. The inside top of the PDC cover has a label showing relay and fuse location. Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3285 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3286 Fuel Pump Relay: Testing and Inspection Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3290 Automatic Shut Down (ASD) Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3291 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3292 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3293 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3294 Automatic Shut Down (ASD) Relay: Description and Operation Fig. 25 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, generator field, electronic ignition coil and the heating elements in the oxygen sensors. Refer to Diagrams/Electrical for circuit information. The Automatic Shutdown (ASD) sense circuit informs the PCM when the ASD relay energizes. When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils, and the heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. OPERATION The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2 Heater Monitor test is being run. When the ignition switch is in On or Start, the PCM momentarily turns on the ASD relay. The PCM also monitors the ASD relay output voltage. If the PCM does not receive 12 volts from this input after grounding the ASD relay, it sets a diagnostic trouble code. While the relay is on the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the PDC Fig. 25. The inside top of the PDC cover has label showing relay and fuse identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3295 Fig. 1 ASD And Fuel Pump Relay Terminals CIRCUIT OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. Power for the coil and contact side of the relay is provided by circuit A14. This circuit is HOT at all times and protected by a 20 amp fuse located in cavity 5 of the PDC. The Powertrain Control Module (PCM) controls the ground path for the relay on circuit K51. This circuit connects to cavity 67 of the PCM connector. When the relay is energized, the contacts internal to the relay close connecting circuits A14 and A142. The A142 circuit is spliced and provides power to the fuel injectors, generator, electronic EGR transducer solenoid, and the ignition coil. The A142 circuit is also spliced and connects to the PCM connector, cavity 6. This input is used for ASD sense by the PCM. HELPFUL INFORMATION Check the 20 amp fuse located in cavity 5 of the PDC. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in cavity 5 of the PDC Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 3298 Automatic Shut Down (ASD) Relay: Testing and Inspection ASD Relay Test Fig. 5 ASD And Fuel Pump Relay Terminals NOTE: The terminals on the bottom of each relay are numbered Fig. 7. OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 75 +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 86 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagrams/Electrical. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Helpful Information > Page 3299 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 1 ASD And Fuel Pump Relay Terminals OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. The PCM grounds the coil side of the relay through terminal number 85. Terminal number 86 supplies voltage to the coil side of the relay. When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Electrical Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation The rollover valves prevent fuel flow through the fuel tank vent valve hoses if the vehicle rolls over. These vehicles are equipped with 2 rollover valves on top of the fuel tank. These valves are not serviceable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation > Page 3303 Rollover Valve: Testing and Inspection Gently shake the valve -- up and down. If the float valve can be heard moving -- knocking -- then the valve is OK. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Output Voltage At idle ................................................................................................................................................... ...................................... greater than 0.6 volts At wide open throttle (WOT) ........................................................................................................................................................... less than 4.5 volts Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3309 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3310 Fig. 23 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3311 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3312 Throttle Position Sensor: Description and Operation Fig. 23 Throttle Position Sensor PURPOSE Along with inputs from other sensors, the PCM uses TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the PCM) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to a maximum of 3.7 volts at wide open throttle. The throttle position sensor mounts to the side of the throttle body Fig. 23. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides a ground path for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 Volts to the A/C pressure switch and the map sensor. On automatic transmission vehicles, circuit K22 is spliced and provides an input to the Transmission Control Module (TCM). Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3315 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be greater than 0.6 volts. - At wide open throttle, TPS output voltage should be less than 4.5 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3316 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3317 Throttle Position Sensor: Service and Repair Fig. 37 Throttle Position Sensor The TPS attaches to the side of the throttle body Fig. 37. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and TPS. 3. Remove throttle body. 4. Remove TPS mounting screws. 5. Remove throttle position sensor. Fig. 38 Indexing Throttle Position Sensor INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 38. - The socket has two tabs inside it. The throttle shaft rests against the tabs. - When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. - The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. - Tighten mounting screws to 2 Nm (17 in. lbs.) torque. NOTE: After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 2. Install throttle body to intake manifold. 3. Attach electrical connectors to idle air control motor and throttle position sensor. 4. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle body bolt torque ...................................................................................................................... ................................................ 28.25 Nm (250 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3321 Throttle Body: Description and Operation Fig. 34 Throttle Body The throttle body mounts to the intake manifold. The throttle position sensor and idle air control motor attach to the throttle body Fig. 34. At above idle conditions, air flow through the throttle body is controlled by a cable operated throttle blade. During closed throttle idle conditions, the idle air control motor control air flow. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3322 Throttle Body: Testing and Inspection Fig. 35 Purge Hose 1. Turn ignition key to Off. 2. Disconnect the PCV valve hose from the intake manifold nipple. Cap the PCV vacuum nipple. 3. Disconnect purge hose from the nipple on the throttle body Fig. 35. Fig. 37 Orifice6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) to the purge nipple on the throttle body Fig. 37. 5. Ensure that all accessories are off. 6. Connect the DRB Scan Tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB Scan Tool, access Minimum Airflow Idle Speed. 9. The following will then occur: - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB Scan Tool displays engine RPM 10. If idle RPM is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. - Below 1,000 miles ............................................................................................................................. ........................................... 450 - 1,100 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 500 - 1,100 rpm 11. If idle RPM is above specifications, use the DRB Scan Tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves. DO NOT let Mopar (TM) Parts Cleaner come in contact with eyes or skin. DO NOT ingest the cleaner. Wash thoroughly after using cleaner. a. Remove the throttle body from engine. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar (TM) Parts Cleaner. Only use Mopar (TM) Parts Cleaner to clean the throttle body. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3323 c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB Scan Tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Replacement Throttle Body: Service and Repair Throttle Body Replacement Fig. 7 Throttle Cable Attachment To Throttle Body REMOVAL 1. Remove air tube from throttle body. 2. Remove throttle cable from the throttle body lever Fig. 7. Fig. 8 Throttle Cable Attachment 3. Pry retainer tab back on throttle cable and slide cable out of bracket Fig. 8. 4. Slide speed control cable out of bracket if equipped Fig. 8. 5. Remove EVAP purge hose from nipple on throttle body. 6. Remove connectors from throttle position sensor and idle air control motor. 7. Remove bolts holding throttle body to intake manifold. Remove throttle body. INSTALLATION 1. Attach electrical connectors to idle air control motor and throttle position sensor. 2. Position throttle body on intake and install mounting bolts. Tighten bolts to 28.25 Nm (250 in. lbs.). 3. Install speed control cable (if equipped) and throttle cable into throttle lever. 4. Install cables into cable bracket. 5. Install air inlet tube. Tighten clamps to 3 ± 0.5 Nm (25 ± 5 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Replacement > Page 3326 Throttle Body: Service and Repair Cleaning Coked Throttle Body - Coked throttle bodies will cause low idle speed and poor idle quality. - Also, if the vehicle has low idle and the idle air control motor operates normally, clean the throttle body before checking throttle body minimum air flow. 1. Remove the throttle body from engine. WARNING: clean throttle body in a well ventilated area. wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. 2. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. 3. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when it is closed, must be free of deposits. 4. Use compressed air to dry the throttle body. 5. Inspect throttle body for foreign material. 6. Install throttle body on manifold. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair Fig. 4 Throttle Cable Attachment To Throttle Body Fig. 5 Throttle Cable Attachment REMOVAL 1. Working from the engine compartment, remove throttle cable from the throttle body lever Fig. 4. 2. Pry retainer tab back on throttle cable and slide cable out of bracket Fig. 5. Fig. 1 Accelerator Pedal And Throttle Cable Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3330 3. From inside the vehicle, reach behind the top of the pedal shaft and push the retainer toward rear of vehicle Fig. 1. It may be necessary to squeeze retainer ears together on dash side of pedal shaft. 4. Lift cable up through slot in top of pedal shaft. 5. From the engine compartment, pull the throttle cable and grommet out of the dash panel. INSTALLATION 1. From the engine compartment, push the cable end fitting and grommet into the dash panel. 2. Install cable housing (throttle body end) into the cable mounting bracket on the engine. 3. Place cable through slot in top of pedal shaft. 4. Step on pedal and retainer will snap into place. 5. From the engine compartment, rotate the throttle lever forward to the wide open position and install cable clasp Fig. 3. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Output Voltage At idle ................................................................................................................................................... ...................................... greater than 0.6 volts At wide open throttle (WOT) ........................................................................................................................................................... less than 4.5 volts Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3335 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3336 Fig. 23 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3337 Throttle Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3338 Throttle Position Sensor: Description and Operation Fig. 23 Throttle Position Sensor PURPOSE Along with inputs from other sensors, the PCM uses TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The Throttle Position Sensor (TPS) connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the PCM) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.5 volt at minimum throttle opening (idle) to a maximum of 3.7 volts at wide open throttle. The throttle position sensor mounts to the side of the throttle body Fig. 23. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides a ground path for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 is spliced and provides 5 Volts to the A/C pressure switch and the map sensor. On automatic transmission vehicles, circuit K22 is spliced and provides an input to the Transmission Control Module (TCM). Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Camshaft position sensor - Manifold absolute pressure sensor - Ambient temperature sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3341 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center terminal of the sensor is the output terminal. With the ignition switch in the ON position, monitor the output voltage at the center terminal wire of the connector -- while slowly moving the throttle from the idle position to Wide Open Throttle (WOT). At idle, TPS output voltage should be greater than 0.6 volts. - At wide open throttle, TPS output voltage should be less than 4.5 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. NOTE: Complete circuit testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3342 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3343 Throttle Position Sensor: Service and Repair Fig. 37 Throttle Position Sensor The TPS attaches to the side of the throttle body Fig. 37. REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and TPS. 3. Remove throttle body. 4. Remove TPS mounting screws. 5. Remove throttle position sensor. Fig. 38 Indexing Throttle Position Sensor INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 38. - The socket has two tabs inside it. The throttle shaft rests against the tabs. - When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body. - The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. - Tighten mounting screws to 2 Nm (17 in. lbs.) torque. NOTE: After installing the TPS, the throttle plate should be closed. If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 2. Install throttle body to intake manifold. 3. Attach electrical connectors to idle air control motor and throttle position sensor. 4. Install EVAP purge hose to throttle body nipple. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Fig. 1 Spark Plug Cable Routing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Fig. 1 Spark Plug Cable Routing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) Camshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3355 Camshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3356 Camshaft Position Sensor: Description and Operation Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. OPERATION This vehicle is equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. The distributor is also equipped with an internal camshaft position (fuel sync) sensor Fig. 2. This sensor provides fuel injection synchronization and cylinder identification to the PCM. The camshaft position sensor contains a hall effect device called a sync signal generator. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the shutter enters the sync signal generator, the interruption of magnetic field causes the voltage to switch high. This causes a sync signal of approximately 5 volts. When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts. Since the shutter rotates at half crankshaft speed, it may take one engine revolution during cranking for the PCM to determine the position of piston number 6. NO CAM SIGNAL AT PCM FAULT MESSAGE Purpose The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. Operation The sensor is provided with 12 volts from the fused ignition switch output circuit and the powertrain control module supplies a sensor ground. The CMP sensor has a 5 volt pull-up from the PCM. The sensor signal is created when the distributor's pulse ring is rotated past the camshaft position sensor. When Monitored: The crankshaft position sensor signal trouble code is not set. With the ignition in either the start or run position and battery voltage between 4 and 15 volts. Set Condition: Too many crankshaft position sensor signals detected without any camshaft position sensor signal Possible Causes: Open fused ignition switch output circuit (12V) - Open sensor ground - Damaged pulse ring - Failed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3357 - Failed PCM - Inoperative distributor drive - Broken timing belt - Connector terminals - Connector wires Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 3360 Camshaft Position Sensor: Service and Repair The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor screw torque ................................................................................................................................................... 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3364 Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3365 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3366 Crankshaft Position Sensor: Description and Operation Fig. 5 Timing Slots Fig. 3 Crankshaft Position Sensor--Adjustable Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3367 Fig 12 Crankshaft Position Sensor Location -- Typical OPERATION The crankshaft position sensor Fig. 3 detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots Fig. 5. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. - The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. - It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The sensor connector has a Christmas tree attached to the heater tube bracket. - The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On automatic transmission vehicles this circuit is spliced and provides an input to the Transmission Control Module (TCM). The PCM provides a ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. HELPFUL INFORMATION The K7 circuit supplies 8 volts to the distributor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 9 Crankshaft Position Sensor REMOVAL 1. Remove speed control servo from driver's side strut tower. 2. Remove crankshaft position sensor retaining bolt Fig. 9. 3. Pull crankshaft position sensor straight up out of the transaxle housing. 4. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. INSTALLATION - ADJUSTABLE Some vehicles may be equipped with an adjustable crankshaft position sensor. This can be identified by an elongated mounting hole in the sensor. Fig. 10 Crankshaft Position Sensor And Spacer If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor Fig. 10. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 2. Connect crankshaft position sensor electrical connector to the wiring harness connector. 3. Attach connector to heater tube bracket. 4. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. INSTALLATION - NON-ADJUSTABLE 1. Install sensor in transaxle. 2. Install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. 4. Attach connector to heater tube bracket. 5. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3372 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 1 Spark Plug Cable Routing Remove the distributor cap and inspect the inside for: flash over - cracking of carbon button - lack of spring tension on carbon button - cracking of cap - burned, worn terminals - Also check for broken distributor cap towers. If any of these conditions are present the distributor cap and/or cables should be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection > Page 3377 Distributor Cap: Service and Repair Fig. 1 Spark Plug Cable Routing When replacing the distributor cap, transfer cables from the original cap to the new cap one at a time. Ensure each cable is installed into the corresponding tower of the new cap. Fully seat the wires into the towers. If necessary refer to the appropriate engine firing order diagram Fig. 1. Light scaling of the terminals can be cleaned with a sharp knife. If the terminals are heavily scaled, replace the distributor cap. A cap that is greasy, dirty or has a powder-like substance on the inside should be cleaned with a solution of warm water and a mild detergent. Scrub the cap with a soft brush. Thoroughly rinse the cap and dry it with a clean soft cloth. Fig. 11 Distributor Cap Screws REMOVAL & INSTALLATION 1. Remove bolt holding air inlet resonator to intake manifold. 2. Loosen clamps holding air cleaner cover to air cleaner housing. 3. Remove PCV make-up air hose from air inlet tube. 4. Loosen hose clamp at throttle body. 5. Remove air inlet tube, resonator and air cleaner cover. 6. Remove EGR tube. 7. Remove spark plug cables from distributor cap. 8. Loosen distributor cap holddown screws and remove cap Fig. 11. 9. Transfer cables from old cap to new cap. The cap is numbered and so are the cables. 10. Install distributor cap. 11. Install distributor holddown washers and nuts. Tighten nuts to 13 Nm (9 ft lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Replace the rotor if: it is cracked - the tip is excessively burned or heavily scaled - the spring terminal does not have adequate tension Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection > Page 3381 Ignition Rotor: Service and Repair Fig. 11 Distributor Cap Screws Fig. 13 Distributor Rotor Button And Spring REMOVAL 1. Remove bolt holding air inlet resonator to intake manifold. 2. Loosen clamps holding air cleaner cover to air cleaner housing. 3. Remove PCV make-up air hose from air inlet tube. 4. Loosen hose clamp at throttle body. 5. Remove air inlet tube, resonator and air cleaner cover. 6. Remove EGR tube. 7. Remove spark plug cables from distributor cap. 8. Loosen distributor cap holddown screws and remove cap Fig. 11. 9. Mark the rotor position and remove rotor. The mark indicates where to position the rotor when reinstalling the distributor. 10. Inspect rotor for cracks or burned electrode. If any of these conditions exist, replace rotor. 11. Inspect rotor button for damage. Replace button and spring as required. Pull button and spring out of cap Fig. 13. 12. Reverse the removal steps for installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 560 Ohms per Inch 3,000 Ohms per Foot 6,700 Ohms per Foot Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3385 Ignition Cable: Description and Operation Spark Plug cables are sometimes referred to as secondary ignition wires. They transfer electrical current from the distributor, to individual spark plugs at each cylinder. They transfer electrical current from the distributor to individual spark plugs at each cylinder. The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Check the spark plug cable connections for good contact at the coil and distributor cap towers and at the spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil and distributor cap towers and spark plug cover should fit tight around spark plug insulators. - Loose cable connections can cause ignition malfunctions by permitting water to enter the towers, corroding, and increasing resistance. 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. Clean high tension cables with a cloth moistened with a non-flammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3388 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from cable clips. 3. Lift distributor cap from distributor with cables intact. Do not remove cables from cap. 4. Connect the ohmmeter between the spark plug end terminal and the corresponding electrode inside the cap. - Make sure ohmmeter probes are 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 the same manner. To test the connection between the coil and distributor terminals: 1. Remove distributor cap. 2. Connect an ohmmeter between center contact in the cap and coil tower terminal. - Resistance should be approximately 5,000 ohms. - If resistance is not within tolerance, replace the cap. - If no problems are found, refer to Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum 250 Ohms per Inch 560 Ohms per Inch 3,000 Ohms per Foot 6,700 Ohms per Foot Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, 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. WARNING: The ignition system generates approximately 32,000 volts. Personal injury could result from contact with this system. 2. With the 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. - Replace cracked, leaking or faulty cables. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Page 3389 Ignition Cable: Service and Repair Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil: Specifications Coil Resistance @ 21-27°C (70-80°F) - Primary .............................................................................................................................................. ............................................. 0.6 to 0.8 ohms - Secondary ......................................................................................................................................... .................................. 12,000 to 18,000 ohms Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Component Locations Ignition Coil: Component Locations Fig. 2 Ignition Coil The ignition coil is located in the distributor housing Fig. 2. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Component Locations > Page 3395 Distributor Connectors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 3396 Distributor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 3397 Ignition Coil: Description and Operation Fig. 10 Ignition Coil OPERATION This engine uses an epoxy type coil. The coils are not oil filled. The windings are embedded in a heat and vibration resistant epoxy compound. The ignition transistor is located in the distributor (pin 11). The PCM controls ignition timing by turning on and off the transistor in the distributor. By switching the ground path for the coil on and off, the PCM adjusts ignition timing to meet changing engine operating conditions. The PCM operates the ignition coil through the Auto Shutdown (ASD) relay. When the relay is energized by the PCM, battery voltage is connected to the ignition coil positive terminal. The PCM will de-energize the ASD relay if it does not receive an input from the distributor pick-up. The ignition coil is located inside the distributor. The distributor is mounted to the right end of the engine block behind the thermostat housing Fig. 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Coil Resistance Test Ignition Coil: Testing and Inspection Coil Resistance Test Fig. 3 Distributor Connectors Measure primary coil resistance at the 2 pin distributor connector. Resistance should be between 0.6 and 0.8 ohms. Measure secondary coil resistance between the coil tower and each terminal of the 2 pin distributor connector. Resistance should be 12k to 18k ohms. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Coil Resistance Test > Page 3400 Ignition Coil: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3401 Ignition Coil: Service and Repair Fig. 2 Ignition Coil The ignition coil is located in the distributor housing Fig. 2. If ignition coil is defective, replace distributor assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) Camshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3406 Camshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3407 Camshaft Position Sensor: Description and Operation Fig. 2 Camshaft Position Sensor -- Inside Distributor (Sync Signal Generator) PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. OPERATION This vehicle is equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. The distributor is also equipped with an internal camshaft position (fuel sync) sensor Fig. 2. This sensor provides fuel injection synchronization and cylinder identification to the PCM. The camshaft position sensor contains a hall effect device called a sync signal generator. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the shutter enters the sync signal generator, the interruption of magnetic field causes the voltage to switch high. This causes a sync signal of approximately 5 volts. When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts. Since the shutter rotates at half crankshaft speed, it may take one engine revolution during cranking for the PCM to determine the position of piston number 6. NO CAM SIGNAL AT PCM FAULT MESSAGE Purpose The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. Operation The sensor is provided with 12 volts from the fused ignition switch output circuit and the powertrain control module supplies a sensor ground. The CMP sensor has a 5 volt pull-up from the PCM. The sensor signal is created when the distributor's pulse ring is rotated past the camshaft position sensor. When Monitored: The crankshaft position sensor signal trouble code is not set. With the ignition in either the start or run position and battery voltage between 4 and 15 volts. Set Condition: Too many crankshaft position sensor signals detected without any camshaft position sensor signal Possible Causes: Open fused ignition switch output circuit (12V) - Open sensor ground - Damaged pulse ring - Failed sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3408 - Failed PCM - Inoperative distributor drive - Broken timing belt - Connector terminals - Connector wires Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Crankshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Page 3411 Camshaft Position Sensor: Service and Repair The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor screw torque ................................................................................................................................................... 12 Nm (105 in lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3415 Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3416 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3417 Crankshaft Position Sensor: Description and Operation Fig. 5 Timing Slots Fig. 3 Crankshaft Position Sensor--Adjustable Fig. 11 Crankshaft Position Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3418 Fig 12 Crankshaft Position Sensor Location -- Typical OPERATION The crankshaft position sensor Fig. 3 detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots Fig. 5. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. - The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. - It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The sensor connector has a Christmas tree attached to the heater tube bracket. - The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On automatic transmission vehicles this circuit is spliced and provides an input to the Transmission Control Module (TCM). The PCM provides a ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. HELPFUL INFORMATION The K7 circuit supplies 8 volts to the distributor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Intake air temperature sensor - Engine coolant temperature sensor - Manifold absolute pressure sensor - Throttle position sensor - A/C pressure switch - Camshaft position sensor - Vehicle speed sensor - Heated oxygen sensors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 9 Crankshaft Position Sensor REMOVAL 1. Remove speed control servo from driver's side strut tower. 2. Remove crankshaft position sensor retaining bolt Fig. 9. 3. Pull crankshaft position sensor straight up out of the transaxle housing. 4. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. INSTALLATION - ADJUSTABLE Some vehicles may be equipped with an adjustable crankshaft position sensor. This can be identified by an elongated mounting hole in the sensor. Fig. 10 Crankshaft Position Sensor And Spacer If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the face of the new sensor Fig. 10. 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 2. Connect crankshaft position sensor electrical connector to the wiring harness connector. 3. Attach connector to heater tube bracket. 4. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. INSTALLATION - NON-ADJUSTABLE 1. Install sensor in transaxle. 2. Install and tighten the retaining bolt to 12 Nm (105 in lb) torque. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. 4. Attach connector to heater tube bracket. 5. Install speed control servo. Tighten nuts to 9 Nm (80 in lb) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3423 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3433 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3434 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3435 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3436 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3437 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3438 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3439 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3440 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3441 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3442 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3443 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3444 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3450 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3451 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3452 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3453 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3454 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3455 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3456 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3457 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3458 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3459 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3460 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3461 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3462 Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3463 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start Lock Cylinder Retaining Tab REMOVAL 1. Disconnect negative cable from auxillary jumper terminal -- on driver's side strut tower. 3. Remove upper steering column shroud. 3. Pull lower shroud down far enough to access lock cylinder retaining tab. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to RUN position (retaining tab on lock cylinder can be depressed). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3464 Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the RUN position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the OFF position. Remove the key. 5. Install steering column shrouds. 5. Connect negative cable to auxillary battery terminal on shock tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .............................. 0.965-1.092 mm (0.038-0.043 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3468 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................. RC10PYP4 Thread size .................................................... ................................................................................................................................................. (14 mm) 3/4 in. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3469 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 1,000 ohm tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Remove the spark plugs and examine them for burned electrodes and 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 recommended intervals. Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. This engine uses platinum spark plugs. CAUTION: Do not attempt to adjust the gap of a platinum plug. Cleaning of the platinum plug may damage the platinum tip. If carbon deposits must be removed, use a plug cleaner and complete cleaning within 20 seconds to protect electrode. Do not use a wire brush. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3472 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3473 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3474 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3475 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. 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 COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3476 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. 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 .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3477 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3478 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection NOTE: 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. - 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 -- SEE Spark Plug Condition. 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 0.038 - 0.043 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3479 Spark Plug Overheating Overheating is indicated by a 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. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3480 Spark Plug: Adjustments Fig 2 Platinum Pads Setting Spark Plug Electrode Gap CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge Fig. 3. - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. - Gap 0.038 to 0.043 in Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3481 Spark Plug: Service and Repair Fig. 3 Intake Manifold Sensors And Left Plenum Support SPARK PLUG SERVICE When replacing the spark plug and coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Do not attempt to adjust the gap of a platinum plug. Cleaning of the platinum plug may damage the platinum tip. If carbon deposits must be removed, use a plug cleaner and complete cleaning within 20 seconds to protect electrode. Do not use a wire brush. SPARK PLUG REMOVAL Remove the spark plugs and examine them for burned electrodes and 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. SPARK PLUG REMOVAL - #2, #4 OR #6 Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1/2 turn and pulling straight back in a steady motion. 1. Prior to removing the spark plug spray compressed air around the spark plug hole and the area around the spark plug. 2. Remove the spark plug using a quality socket with a rubber or foam insert. 3. Inspect the spark plug condition. SPARK PLUG REMOVAL - #1, #3 OR #5 1. Disconnect negative cable from auxiliary jumper terminal. 2. Unplug connectors from MAP and intake air temperature sensors Fig. 3. 3. Remove plenum support bracket bolt located rearward of MAP sensor Fig. 3. 4. Remove bolt holding air inlet resonator to intake plenum Fig. 4. Fig. 4 Air Inlet Resonator 5. Loosen throttle body air inlet hose clamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3482 6. Release snaps holding air cleaner housing cover to housing. 7. Remove air cleaner cover and inlet hoses from engine. 8. Unplug TPS and idle air control motor connectors Figs. 5 and 6. 9. Pry retainer tab back on throttle cable and slide cable out of bracket Fig. 7. Remove cable from throttle lever. 10. Slide Speed control cable out of bracket, if equipped Fig. 7. Remove cable from throttle lever. 11. Remove EGR tube from intake plenum Fig. 8. Fig. 5 Throttle Sensor Position Sensor Fig. 6 Idle Air Control Module Fig. 7 Throttle Cable Attachment 12. Remove plenum support bracket bolt located rearward of EGR tube Fig. 8. 13. Remove bolts holding upper intake plenum and remove plenum. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3483 Fig. 8 EGR Tube And Right Manifold Support Bolt 14. Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1/2 turn and pulling straight back in a steady motion. 15. Prior to removing the spark plug spray compressed air around the spark plug hole and the area around the spark plug. 16. Remove the spark plug using a quality socket with a rubber or foam insert. 17. Inspect the spark plug condition. Fig 2 Platinum Pads SPARK PLUG INSTALLATION CAUTIONS: - Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. - Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. - Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicles original spark plugs that have been determined good. Do not apply anti-seize compound to new spark plugs. - Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the anti- seize compound doesn't make contact with the spark plug electrodes or ceramic insulator. - Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without following the correct procedures. - Always tighten spark plugs to the specified torque Over tightening can cause distortion resulting in a change in the spark plug gap. Over tightening can also damage the cylinder head. Tighten spark plugs to 28 Nm (20 ft. lbs.) torque. - Due to the engine packaging environment for these engines. extreme care should be used when installing the spark plugs to avoid cross threading problems. 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install ignition cables over spark plugs. 4. Install new gasket and position upper intake plenum. Tighten plenum bolts to 18 Nm (13 ft lb) torque. 5. Install bolts at plenum support brackets. Tighten bolts to 18 Nm (13 ft lb). 6. Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 in lb). 7. Install throttle and speed control (if equipped) cables. 8. Attach electrical connectors to sensors. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3484 9. Tighten air inlet tube clamps to 2-4 Nm (20-30 in lb) torque. 10. Connect negative terminal to auxiliary jumper terminal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Locations > Page 3491 Transmission Solenoid Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION PRNDL (Electronic) On vehicles equipped with an automatic transmission an electronic PRNDL is used to indicate to the operator gearshift position. When the ignition switch is in the OFF (unlock), RUN, or START position the Body Control Module (BCM) transmits a message over the CCD Bus instructing the instrument cluster to illuminate the proper display The BCM receives its information over the CCD Bus from the Transmission Control Module (TCM). When the ignition switch is moved to the RUN position, the BCM instructs the instrument cluster to illuminate all segments of the PRNDL as a check. PRNDL Illumination The PRNDL illumination is handled by a Light Emitting Diode (LED) and receives power on the E2 circuit from the Body Control Module (BCM). This circuit is HOT when the operator has turned the headlamp switch to the PARK or ON position. Lamp intensity is controlled by the input of the dimmer switch to the BCM on circuit E19. Ground for the LED is provided by the Z1 circuit. This circuit terminates at the instrument panel left side cowl after passing through the ground joint in the junction block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb Shift Indicator: Service and Repair Floor PRNDL Bezel Lamp Bulb The floor PRNDL bezel lamp has no service able bulb. If the lamp does not function properly, the PRNDL bezel assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb > Page 3499 Shift Indicator: Service and Repair Floor PRNDL Lamp REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of PRNDL bezel from floor console. 3. Pull upward carefully on PRNDL bezel and disengage tabs from rear floor console bezel. 4. Disengage wire connector to lamp assembly. 5. Separate PRNDL bezel and lamp assembly from vehicle. INSTALLATION 1. Position PRNDL and lamp assembly to vehicle. 2. Engage wire connector to lamp assembly. 3. Engage tabs on PRNDL bezel to slots in rear floor console bezel. 4. Push downward on PRNDL bezel to engage to bezel to floor console. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator Transmission Mode Indicator - A/T: Service and Repair Odometer/Transmission Range Indicator REMOVAL 1. Remove speedometer/tachometer. Odometer/Transmision Range Indicator 2. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 3504 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 3505 Odometer/Transmision Range Indicator 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3516 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3517 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3523 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3524 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3527 Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3528 Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3529 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3530 Fuse Block PCM Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3531 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3534 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3535 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3536 Part 2 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3537 Part 3 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3538 Part 4 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3539 Part 5 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3540 Part 6 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3541 Part 7 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3542 Part 8 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3543 Part 9 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 3544 Part 11 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3547 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3548 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3549 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3550 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3551 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3552 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3553 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3554 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3555 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3556 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3557 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3558 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3559 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, 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 over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3560 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3563 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3567 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3568 Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Locations Autostick Switch Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Locations > Page 3574 Autostick Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3583 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3584 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3585 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3591 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3592 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3597 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3598 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3599 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3605 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3606 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 3607 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3610 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 3611 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 3612 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 3613 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 3614 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3623 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3628 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3629 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3630 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3636 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3641 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3642 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3643 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3644 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3645 Input / Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3648 Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3649 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3661 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3662 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3663 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-18-98 > Apr > 98 > PCM - Excessive Crank Time/Start Die Out/Weak Run Up Technical Service Bulletin # 18-18-98 Date: 980410 PCM - Excessive Crank Time/Start Die Out/Weak Run Up NO: 18-18-98 GROUP: Vehicle Performance DATE: Apr. 10, 1998 SUBJECT: Excessive Cold Crank Time, Start Die Out Or Weak Run Up, Sags/Stumble/Hesitation After A Cold Start, Idle RPM Cycling MODELS: 1997 - 1998 (FJ) Avenger/Sebring 1997 - 1998 (JA) Cirrus/Stratus/Breeze 1997 - 1998 (JX) Sebring Convertible NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.5L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (FJ) DEC. 10, 1997 (MDH 1210XX), (JA) MAR.25, 1998 (MDH 0325XX), AND (JX) FEDERAL CALIBRATION NOV. 25, 1997 (MDH 1125XX) - (JX) CALIFORNIA/NORTHEAST CALIBRATION MAR. 3, 1998 (MDH 0303XX). SYMPTOM/CONDITION: 1997 MODELS: 1. (FJ/JA/JX) - Excessive cold crank time (excess of 30 seconds) followed by a very rough idle or excessive cold crank time with a no start condition. This may be caused by no/low compression due to loose carbon holding valves open. Performing a clear flood procedure (WOT Start) will allow the vehicle to start. This condition typically follows a cold start with an engine run time of less than 60 seconds. An example of this would be pulling the vehicle from a garage to the driveway and turning the engine off. The subsequent start may experience the condition. 2. (FJ/JA/JX) - Sags, stumble, or hesitation after a cold start in ambient temperatures of 4 to 32 C (40 to 90 F). This condition may persist for up to a minute into a drive cycle and is attributed to high driveability index (DI) fuel. 3. (JA/JX) - Die out or very weak run up during partial cool downs or hot starts. This may be experienced with coolant temperatures between 65 to 82 C (150 to 180 F). 1998 MODELS: 1. (FJ/JA/JX) - Excessive cold crank time (excess of 30 seconds) followed by a very rough idle or excessive cold crank time with a no start condition. This may be caused by no/low compression due to loose carbon holding valves open. Performing a clear flood procedure (WOT Start) will allow the vehicle to start. This condition typically follows a cold start with an engine run time of less than 60 seconds. An example of this would be pulling the vehicle from a garage to the driveway and turning the engine off. The subsequent start may experience the condition. 2. (FJ/JA/JX) - Sags, stumble, or hesitation after a cold start in ambient temperatures of 4 to 32 C (40 to 90 F). This condition may persist for up to a minute into a drive cycle and is attributed to high driveability index (DI) fuel. 3. (JA/JX) - Idle RPM cycling of +/- 300 RPM in hot ambient conditions with the AC compressor engaged. 4. (JA/JX) - Die out or weak run up during cold starts in ambient temperatures of -18 to 10C (0 to 50 F). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III(R) with the appropriate Diagnostic Procedures 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 DTC's are present and any of the symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-18-98 > Apr > 98 > PCM - Excessive Crank Time/Start Die Out/Weak Run Up > Page 3668 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1156 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedures This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III(R) 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) 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(R) 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 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-18-98 > Apr > 98 > PCM - Excessive Crank Time/Start Die Out/Weak Run Up > Page 3669 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-11-97 > Feb > 97 > MIL - Erroneously ON, Hex Codes #6A/#77 Set Technical Service Bulletin # 18-11-97 Date: 970228 MIL - Erroneously ON, Hex Codes #6A/#77 Set NO: 18-11-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Erroneous MIL Illumination With Hex Codes $6A, $77, Erroneous PCM Resets, Shift Cycling, Cold Engine Stumble, Bucking MODELS: 1997 (FJ) Avenger/Sebring 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 31, 1997 (MDH 01-31-XX) WITH THE FOLLOWING ENGINE APPLICATIONS: FJ JA/JX 2.5L 2.0L/2.4L/2.5L SYMPTOM/CONDITION: 1. 2.0L MTX - Bucking during parking lot maneuvers (first/second gear), difficult to drive smoothly. 2. 2.4L - Erroneous MIL illumination with DTC RIGHT REAR (OR JUST) FUEL SYSTEM LEAN Hex $77. 3. 2.4L/2.5L - Erroneous MIL illumination with DTC MULTIPLE CYLINDER MIS-FIRE - Hex $6A. 4. 2.4L/2.5L - Shift cycling between 2nd and 3rd gear with resume of Interactive Cruise Control above 20 MPH on a grade. 5. 2.4L/2.5L - Engine stumble within 10 seconds of a cold start. If this condition persists after repair, it is recommended to change fuel brands. 6. 2.0L/2.4L/2.5L - Engine stumble or miss at idle or open throttle at 2 minute intervals. This condition can only occur after a fuel system (rich/lean) fault (MIL) has been set and the condition corrects itself after 3 good OBD II trips or a technician makes repairs and does not erase the faults. The stumble occurs after 3 good OBD II defined trips at which time the engine control module does a reset every 2 minutes during a drive cycle. 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 and any of the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED, DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962/MMC 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 1127 OR HIGHER MUST BE INSTALLED. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-11-97 > Feb > 97 > MIL - Erroneously ON, Hex Codes #6A/#77 Set > Page 3674 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-91 0.5 Hrs. FAILURE CODE: FM - Flash Module 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. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3680 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3681 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3682 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3683 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3684 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3685 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3686 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3687 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3688 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3689 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3690 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3691 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3692 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3693 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3694 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3695 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3696 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3697 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3698 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3703 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3704 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3705 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-18-98 > Apr > 98 > PCM - Excessive Crank Time/Start Die Out/Weak Run Up Technical Service Bulletin # 18-18-98 Date: 980410 PCM - Excessive Crank Time/Start Die Out/Weak Run Up NO: 18-18-98 GROUP: Vehicle Performance DATE: Apr. 10, 1998 SUBJECT: Excessive Cold Crank Time, Start Die Out Or Weak Run Up, Sags/Stumble/Hesitation After A Cold Start, Idle RPM Cycling MODELS: 1997 - 1998 (FJ) Avenger/Sebring 1997 - 1998 (JA) Cirrus/Stratus/Breeze 1997 - 1998 (JX) Sebring Convertible NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.5L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (FJ) DEC. 10, 1997 (MDH 1210XX), (JA) MAR.25, 1998 (MDH 0325XX), AND (JX) FEDERAL CALIBRATION NOV. 25, 1997 (MDH 1125XX) - (JX) CALIFORNIA/NORTHEAST CALIBRATION MAR. 3, 1998 (MDH 0303XX). SYMPTOM/CONDITION: 1997 MODELS: 1. (FJ/JA/JX) - Excessive cold crank time (excess of 30 seconds) followed by a very rough idle or excessive cold crank time with a no start condition. This may be caused by no/low compression due to loose carbon holding valves open. Performing a clear flood procedure (WOT Start) will allow the vehicle to start. This condition typically follows a cold start with an engine run time of less than 60 seconds. An example of this would be pulling the vehicle from a garage to the driveway and turning the engine off. The subsequent start may experience the condition. 2. (FJ/JA/JX) - Sags, stumble, or hesitation after a cold start in ambient temperatures of 4 to 32 C (40 to 90 F). This condition may persist for up to a minute into a drive cycle and is attributed to high driveability index (DI) fuel. 3. (JA/JX) - Die out or very weak run up during partial cool downs or hot starts. This may be experienced with coolant temperatures between 65 to 82 C (150 to 180 F). 1998 MODELS: 1. (FJ/JA/JX) - Excessive cold crank time (excess of 30 seconds) followed by a very rough idle or excessive cold crank time with a no start condition. This may be caused by no/low compression due to loose carbon holding valves open. Performing a clear flood procedure (WOT Start) will allow the vehicle to start. This condition typically follows a cold start with an engine run time of less than 60 seconds. An example of this would be pulling the vehicle from a garage to the driveway and turning the engine off. The subsequent start may experience the condition. 2. (FJ/JA/JX) - Sags, stumble, or hesitation after a cold start in ambient temperatures of 4 to 32 C (40 to 90 F). This condition may persist for up to a minute into a drive cycle and is attributed to high driveability index (DI) fuel. 3. (JA/JX) - Idle RPM cycling of +/- 300 RPM in hot ambient conditions with the AC compressor engaged. 4. (JA/JX) - Die out or weak run up during cold starts in ambient temperatures of -18 to 10C (0 to 50 F). DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III(R) with the appropriate Diagnostic Procedures 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 DTC's are present and any of the symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-18-98 > Apr > 98 > PCM - Excessive Crank Time/Start Die Out/Weak Run Up > Page 3710 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1156 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-92 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedures This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III(R) 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) 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(R) 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 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-18-98 > Apr > 98 > PCM - Excessive Crank Time/Start Die Out/Weak Run Up > Page 3711 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-11-97 > Feb > 97 > MIL - Erroneously ON, Hex Codes #6A/#77 Set Technical Service Bulletin # 18-11-97 Date: 970228 MIL - Erroneously ON, Hex Codes #6A/#77 Set NO: 18-11-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Erroneous MIL Illumination With Hex Codes $6A, $77, Erroneous PCM Resets, Shift Cycling, Cold Engine Stumble, Bucking MODELS: 1997 (FJ) Avenger/Sebring 1997 (JA) Breeze/Cirrus/Stratus 1997 (JX) Sebring Convertible NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JAN. 31, 1997 (MDH 01-31-XX) WITH THE FOLLOWING ENGINE APPLICATIONS: FJ JA/JX 2.5L 2.0L/2.4L/2.5L SYMPTOM/CONDITION: 1. 2.0L MTX - Bucking during parking lot maneuvers (first/second gear), difficult to drive smoothly. 2. 2.4L - Erroneous MIL illumination with DTC RIGHT REAR (OR JUST) FUEL SYSTEM LEAN Hex $77. 3. 2.4L/2.5L - Erroneous MIL illumination with DTC MULTIPLE CYLINDER MIS-FIRE - Hex $6A. 4. 2.4L/2.5L - Shift cycling between 2nd and 3rd gear with resume of Interactive Cruise Control above 20 MPH on a grade. 5. 2.4L/2.5L - Engine stumble within 10 seconds of a cold start. If this condition persists after repair, it is recommended to change fuel brands. 6. 2.0L/2.4L/2.5L - Engine stumble or miss at idle or open throttle at 2 minute intervals. This condition can only occur after a fuel system (rich/lean) fault (MIL) has been set and the condition corrects itself after 3 good OBD II trips or a technician makes repairs and does not erase the faults. The stumble occurs after 3 good OBD II defined trips at which time the engine control module does a reset every 2 minutes during a drive cycle. 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 and any of the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED, DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962/MMC 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 1127 OR HIGHER MUST BE INSTALLED. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 18-11-97 > Feb > 97 > MIL - Erroneously ON, Hex Codes #6A/#77 Set > Page 3716 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-91 0.5 Hrs. FAILURE CODE: FM - Flash Module 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. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3722 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3723 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3724 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3725 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3726 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3727 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3728 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3729 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3730 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3731 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3732 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3733 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3734 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3735 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3736 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3737 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3738 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3739 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3740 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3747 Transmission Solenoid Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3753 Transmission Solenoid Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch Clutch: Specifications Low Reverse Clutch Clutch Retainer .................................................................................................................................... .................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch > Page 3758 Clutch: Specifications 4 Speed Automatic CLUTCH PACK CLEARANCES: L/R (Select Reaction Plate) ....................................................................................................................................... 0.89 - 1.04 mm (0.035 - 0.042 inch) 2/4 (No Selection) ..................................................................................................................................................... 0.76 - 2.64 mm (0.030 - 0.104 inch) Reverse (Select Snap Ring) ....................................................................................................................................... 0.76 - 1.24 mm (0.030 - 0.049 inch) Overdrive (No Selection) .......................................................................................................................................... 0.96 - 2.26 mm (0.038 - 0.089 inch) Underdrive (Select Pressure Plate) ............................................................................................................................ 0.91 - 1.47 mm (0.036 - 0.058 inch) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3761 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3762 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3763 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3764 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3773 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3774 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3780 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3781 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3784 Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3785 Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3786 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3787 Fuse Block PCM Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3788 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3791 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3792 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3793 Part 2 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3794 Part 3 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3795 Part 4 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3796 Part 5 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3797 Part 6 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3798 Part 7 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3799 Part 8 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3800 Part 9 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3801 Part 11 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3804 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3805 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3806 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3807 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3808 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3809 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3810 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3811 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3812 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3813 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3814 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3815 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3816 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, 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 over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3817 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > General Information > Page 3820 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations Data Link Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations > Page 3824 Data Link Connector (16 - Way) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Carrier Assembly, A/T > Carrier Bearings, A/T > Component Information > Specifications Carrier Bearings: Specifications Retainer Bolts ...................................................................................................................................... ..................................................... 28 Nm (21 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Case, A/T > Component Information > Specifications Differential Case: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 19 Nm (165 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Ring Gear, A/T > Component Information > Specifications Ring Gear: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 95 Nm (70 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 28 Nm (21 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3843 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3844 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3845 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3846 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3847 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3848 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3849 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Transmission Fluid Service Refill Capacity ......................................................................................................................... ............................................................. 3.8L (4.0 Qt) Initial Refill Capacity Transmission Fluid Initial Refill Capacity ............................................................................................................................ ............................................................ 3.8L (4.0 Qt) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3852 Fluid - A/T: Fluid Type Specifications Oil Type ........................................................................................................................................................... MOPAR ATF+4 Type 9602, Or Equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 3855 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 3856 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > A/T - 41TE/42LE Shudder During EMCC Shift > Page 3861 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 3864 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Fittings ................................................................................................................................................. ............................................... 12 Nm (105 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 3868 Fluid Line/Hose: Service and Repair FLUSHING COOLERS AND TUBES When a transaxle failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler bypass valve in the transaxle must be replaced also. The torque converter must also be replaced with an exchange unit. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transaxle. The recommended procedure for flushing the transaxle cooler is to use Tool 6906A Cooler Flusher. WARNING: Wear protective eye-wear that meets the requirements of OSHA and ANSI Z87.1-1968. wear standard industrial rubber gloves. - Keep lighted cigarettes, sparks, flames, and other ignition sources away from the area to prevent the ignition of combustible liquids and gases. Keep a class (B) fire extinguisher in the area where the flusher will be used. - Keep the area well ventilated. - Do not let flushing solvent come in contact with your eyes or skin: if eye contamination occurs, flush eyes with water for 15 to 20 seconds. Remove contaminated clothing and wash affected skin with soap and water. Seek medical attention. COOLER FLUSH USING TOOL 6906A 1. Remove cover plate filler plug on Tool 6906A, or equivalent. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906A. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of MOPAR ATF+4 Type 9602 automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. 14. Check for debris on cooler and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Oil Pan Bolts 14 ft.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3880 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3881 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3882 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3888 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3889 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3890 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 3891 Fluid Pump: Specifications CLEARANCES: Outer Gear To Pocket ....................................................................................................................................... 0.045 - 0.141 mm (0.0018 - 0.0056 inch) Outer Gear Side Clearance ................................................................................................................................ 0.020 - 0.046 mm (0.0008 - 0.0018 inch) Inner Gear Side Clearance ................................................................................................................................ 0.020 - 0.046 mm (0.0008 - 0.0018 inch) TIGHTENING TORQUE: Mounting Bolts ..................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 3892 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 3893 Fluid Pump: Testing and Inspection After the new or repaired transmission has been installed, fill to the proper level with MOPAR ATF+4 (Type 9602), or equivalent automatic transmission fluid. The volume should be checked using the following procedure: 1. Disconnect the From cooler line at the transmission and place a collecting container under the disconnected line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 2. Run the engine at curb idle speed, with the shift selector in neutral. 3. If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF, disconnect the To Cooler line at the transaxle. 4. Refill the transaxle to proper level and recheck pump volume. 5. If flow is found to be within acceptable limits, replace the cooler. Then fill.transmission to the paper level, using. MOPAR ATF+4 (Type 9602), or equivalent automatic transmission fluid. 6. If fluid flow is still found-to be inadequate, check the line pressure using the Transaxle Hydraulic Pressure Test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION PRNDL (Electronic) On vehicles equipped with an automatic transmission an electronic PRNDL is used to indicate to the operator gearshift position. When the ignition switch is in the OFF (unlock), RUN, or START position the Body Control Module (BCM) transmits a message over the CCD Bus instructing the instrument cluster to illuminate the proper display The BCM receives its information over the CCD Bus from the Transmission Control Module (TCM). When the ignition switch is moved to the RUN position, the BCM instructs the instrument cluster to illuminate all segments of the PRNDL as a check. PRNDL Illumination The PRNDL illumination is handled by a Light Emitting Diode (LED) and receives power on the E2 circuit from the Body Control Module (BCM). This circuit is HOT when the operator has turned the headlamp switch to the PARK or ON position. Lamp intensity is controlled by the input of the dimmer switch to the BCM on circuit E19. Ground for the LED is provided by the Z1 circuit. This circuit terminates at the instrument panel left side cowl after passing through the ground joint in the junction block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb Shift Indicator: Service and Repair Floor PRNDL Bezel Lamp Bulb The floor PRNDL bezel lamp has no service able bulb. If the lamp does not function properly, the PRNDL bezel assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb > Page 3900 Shift Indicator: Service and Repair Floor PRNDL Lamp REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of PRNDL bezel from floor console. 3. Pull upward carefully on PRNDL bezel and disengage tabs from rear floor console bezel. 4. Disengage wire connector to lamp assembly. 5. Separate PRNDL bezel and lamp assembly from vehicle. INSTALLATION 1. Position PRNDL and lamp assembly to vehicle. 2. Engage wire connector to lamp assembly. 3. Engage tabs on PRNDL bezel to slots in rear floor console bezel. 4. Push downward on PRNDL bezel to engage to bezel to floor console. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator Transmission Mode Indicator - A/T: Service and Repair Odometer/Transmission Range Indicator REMOVAL 1. Remove speedometer/tachometer. Odometer/Transmision Range Indicator 2. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 3905 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 3906 Odometer/Transmision Range Indicator 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 3911 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 3912 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3922 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3923 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3929 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 3930 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3933 Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3934 Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3935 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3936 Fuse Block PCM Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3937 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3940 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3941 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3942 Part 2 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3943 Part 3 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3944 Part 4 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3945 Part 5 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3946 Part 6 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3947 Part 7 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3948 Part 8 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3949 Part 9 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3950 Part 11 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3953 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3954 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3955 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3956 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3957 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3958 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3959 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3960 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3961 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3962 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3963 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3964 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3965 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, 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 over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3966 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3969 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3973 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3974 Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3983 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3984 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3985 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3991 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3996 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3997 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 3998 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4004 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4005 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4006 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4007 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4008 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4009 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4010 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4011 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4012 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Page 4013 Seals and Gaskets: Service and Repair Remove Oil Pump Seal Install Oil Pump Seal Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations Autostick Switch Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4018 Autostick Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4027 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4028 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4029 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4035 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4036 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4041 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4042 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4043 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 08-06-98 > Feb > 98 > A/C - EBL Indicator Bulb Does Not Light 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 08-06-98 > Feb > 98 > A/C - EBL Indicator Bulb Does Not Light > Page 4049 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 08-06-98 > Feb > 98 > A/C - EBL Indicator Bulb Does Not Light > Page 4050 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4051 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4054 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4055 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4056 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4057 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4058 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4067 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4072 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4073 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4074 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4080 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4085 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4086 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4087 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4088 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4089 Input / Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4092 Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4093 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Technical Service Bulletins > Gearshift Service - Mandatory Battery Disconnecting Shift Interlock Cable: Technical Service Bulletins Gearshift Service - Mandatory Battery Disconnecting NO: 21-16-96 GROUP: Transmission DATE: Nov. 15, 1996 SUBJECT: Gearshift Service/ Battery Disconnect MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible DISCUSSION: The Airbag Control Module (ACM) is located in the floor console near the transmission gearshift linkage. Any sudden impact or vibration near the ACM with the key in the run position may cause airbag deployment. In order to prevent possible airbag deployment during the following gearshift related service procedures, the battery must be disconnected: ^ Gearshift cable adjustment ^ Gearshift cable replacement ^ Shifter ignition interlock cable adjustment ^ Shifter ignition interlock cable replacement ^ Gearshift mechanism replacement POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Technical Service Bulletins > Page 4102 Shift Interlock Cable: Service and Repair REMOVAL 1. Disconnect and isolate, the battery negative (-) cable at the left side strut tower. 2. Remove the gearshift knob set screw and knob. 3. Remove console assembly. Refer to Service Manual for procedure. 4. Unsnap the shifter / ignition interlock cable end fitting from the groove in the gearshift mechanism. 5. Remove the cable core end from the plastic cam of the shifter mechanism. 6. Pull cable up and out of the gearshift mechanism. 7. Remove fuse panel cover from the left end of the instrument panel. Remove screw holding end of instrument panel top cover. 8. Pull center bezel off. 9. Remove screws holding instrument panel top cover to center of Instrument panel. 10. Pull instrument panel top cover up enough to gain access to knee bolster screws. 11. Remove lower knee bolster screws and knee bolster. 12. Remove screws from lower steering column shroud. 13. Pull lower shroud to clear ignition cylinder. 14. Hold tilt wheel lever down and slide lower shroud forward to remove it from column. 15. Tilt wheel to full down position and remove upper steering column shroud. 16. Verify vehicle ignition is on. Grasp the interlock cable clip and connector. Remove the cable from the interlock housing. 17. Unclip the cable retaining clip located along the cable housing. 18. Remove the interlock cable from underside of instrument panel. CAUTION: When installing interlock cable assembly, care must be taken not to bend exposed cable wire and slug at shifter end of cable. INSTALLATION 1. Route interlock cable into lower dash panel. 2. Turn the ignition switch to the RUN position. 3. Install the interlock cable into the interlock housing at the steering column. Verify the cable snaps into the housing. 4. Install interlock cable into routing clip located along cable housing. 5. Route interlock cable to the console. 6. Install the cable core end to the plastic cam of the shifter mechanism. Snap the shifter / ignition interlock cable end fitting into the groove in the gearshift mechanism. 7. Adjust the Shifter ignition / Interlock System. 8. Perform the Shifter / Interlock System operation check. 9. Install console assembly. 10. Install gearshift knob set screw and knob. 11. Tilt wheel to full down position and install upper steering wheel shroud. 12. Hold tilt wheel lever down and slide lower shroud in at column. 13. Install screws at lower steering column shroud. 14. Install lower knee bolster screws and knee bolster. 15. Install screws holding instrument panel top cover to center of instrument panel. 16. Install center bezel. 17. Install screw holding end of instrument panel top cover. Install fuse panel cover from left end of instrument panel. 18. Reconnect the battery negative (-) cable to the vehicle battery. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4106 Transmission Solenoid Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4115 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4116 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4117 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4118 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4119 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4120 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4121 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4122 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4123 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4124 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4125 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4126 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Component Information > Specifications Axle Nut: Specifications Tightening 1995-96 Stratus/Cirrus/Breeze .............................................................................................................................................244 Nm (180 ft. lbs.) Tightening 1997 Stratus/Cirrus/Breeze ........................................................................................................... 203 Nm (150 ft. lbs.) to 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4138 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4139 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4140 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4141 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4142 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4143 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4144 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4145 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4146 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4147 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4148 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 08-08-97 > Feb > 97 > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4149 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1,000 miles ................................................................................ .............................................................................................. 450 - 1,100 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 500 - 1,100 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > System Information > Specifications > Page 4152 Idle Speed: Testing and Inspection Fig. 35 Purge Hose 1. Turn ignition key to Off. 2. Disconnect the PCV valve hose from the intake manifold nipple. Cap the PCV vacuum nipple. 3. Disconnect purge hose from the nipple on the throttle body Fig. 35. Fig. 37 Orifice6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) to the purge nipple on the throttle body Fig. 37. 5. Ensure that all accessories are off. 6. Connect the DRB Scan Tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB Scan Tool, access Minimum Airflow Idle Speed. 9. The following will then occur: - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB Scan Tool displays engine RPM 10. If idle RPM is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. - Below 1,000 miles ............................................................................................................................. ........................................... 450 - 1,100 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 500 - 1,100 rpm 11. If idle RPM is above specifications, use the DRB Scan Tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves. DO NOT let Mopar (TM) Parts Cleaner come in contact with eyes or skin. DO NOT ingest the cleaner. Wash thoroughly after using cleaner. a. Remove the throttle body from engine. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar (TM) Parts Cleaner. Only use Mopar (TM) Parts Cleaner to clean the throttle body. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > System Information > Specifications > Page 4153 c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB Scan Tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Gearshift Service - Mandatory Battery Disconnecting Shift Cable: Technical Service Bulletins Gearshift Service - Mandatory Battery Disconnecting NO: 21-16-96 GROUP: Transmission DATE: Nov. 15, 1996 SUBJECT: Gearshift Service/ Battery Disconnect MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible DISCUSSION: The Airbag Control Module (ACM) is located in the floor console near the transmission gearshift linkage. Any sudden impact or vibration near the ACM with the key in the run position may cause airbag deployment. In order to prevent possible airbag deployment during the following gearshift related service procedures, the battery must be disconnected: ^ Gearshift cable adjustment ^ Gearshift cable replacement ^ Shifter ignition interlock cable adjustment ^ Shifter ignition interlock cable replacement ^ Gearshift mechanism replacement POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4162 Shift Cable: Adjustments 1. Set parking brake, then remove gearshift knob set screw and knob. 2. Remove gearshift selector bezel and lamp wiring. 3. Install gearshift knob and set screw. 4. Place gearshift in P park position, then loosen gearshift cable adjuster nut at shifter assembly. 5. Ensure shifter and transaxle are in P park position, then tighten nut at shifter assembly. 6. Inspect adjustment as follows: a. Detent position for neutral and drive should be with in limits of hand lever gate stops. b. Key start must occur only when shift lever is in park or neutral positions. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4163 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4164 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Description and Operation > Front Sun Gear Assembly > Page 4169 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Diameter .............................................................................................................................................. ................................................ 241 mm (9.48 inches) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4173 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4178 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4182 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4183 Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Hose Clamps ....................................................................................................................................... .................................................... 2 Nm (18 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4187 Transmission Cooler: Description and Operation Is a external oil-to-air type mounted ahead of the cooling module. This style cooler uses steel tube and rubber oil lines to feed oil from the internal cooler to the external and then to the automatic transmission. Use only approved transmission oil cooler hose. NOTE: Since these are molded to fit space available, molded hoses are recommended. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4188 Transmission Cooler: Service and Repair FLUSHING COOLERS AND TUBES When a transaxle failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler bypass valve in the transaxle must be replaced also. The torque converter must also be replaced with an exchange unit. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transaxle. The recommended procedure for flushing the transaxle cooler is to use Tool 6906A Cooler Flusher. WARNING: Wear protective eye-wear that meets the requirements of OSHA and ANSI Z87.1-1968. wear standard industrial rubber gloves. - Keep lighted cigarettes, sparks, flames, and other ignition sources away from the area to prevent the ignition of combustible liquids and gases. Keep a class (B) fire extinguisher in the area where the flusher will be used. - Keep the area well ventilated. - Do not let flushing solvent come in contact with your eyes or skin: if eye contamination occurs, flush eyes with water for 15 to 20 seconds. Remove contaminated clothing and wash affected skin with soap and water. Seek medical attention. COOLER FLUSH USING TOOL 6906A 1. Remove cover plate filler plug on Tool 6906A, or equivalent. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906A. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of MOPAR ATF+4 Type 9602 automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. 14. Check for debris on cooler and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator Transmission Mode Indicator - A/T: Service and Repair Odometer/Transmission Range Indicator REMOVAL 1. Remove speedometer/tachometer. Odometer/Transmision Range Indicator 2. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 4193 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 4194 Odometer/Transmision Range Indicator 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations Autostick Switch Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Locations > Page 4198 Autostick Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4207 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4208 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4209 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4215 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4216 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4221 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4222 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4223 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4229 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4230 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4231 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4234 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4235 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4236 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4237 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4238 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4250 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4255 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4256 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4257 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4263 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4268 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4269 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4270 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4271 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4272 Input / Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 4275 Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4276 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4288 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4289 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4290 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4296 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4297 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4298 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4299 Valve Body: Specifications Valve Body To Case Bolts ................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Valve Body Bolts .............................................. ...................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4300 A604 (41TE) 4 Speed Transaxle Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4301 A604 (41TE) 4 Speed Transaxle Solenoid Pack Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4304 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4305 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4306 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4307 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4308 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4309 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4310 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4311 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4314 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4315 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4316 Valve Body: Service and Repair Cleaning and Inspection CLEANING VALVE BODY Prior to removing any transaxle parts, plug all openings and clean unit, preferably by steam. Cleanliness through entire disassembly and assembly cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the transaxles are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs. NOTE: Tag all springs, as they are removed, for reassembly identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4317 Valve Body: Service and Repair Solenoid Assembly Replacement REMOVAL Input Speed Sensor Removed Remove Sound Cover Remove Attaching Screws Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4318 Remove Solenoid Assembly INSTALLATION To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4319 Valve Body: Service and Repair 41TE 4-Speed Transmission Range Sensor Screw Transmission Range Sensor Removed Manual Shaft And Rooster Comb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4320 2-4 Accumulator Plate TRS, Manual Shaft, And 2-4 Accumulator Valve Body Screws Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4321 Valve Body And Transfer Plate Transfer Plate And Separator Plate Ball Check Location Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4322 Springs And Valves Location Remove Or Install Dual Retainer Plate TC Limit Valve And Low/Reverse Switch Valve Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Adjustments Clutch Cable: Adjustments The clutch cable has a self-adjusting mechanism built into the cable which compensates for clutch disc wear. The cable requires no maintenance or lubrication and is not adjustable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Adjustments > Page 4327 Clutch Cable: Service and Repair 1. Remove air cleaner assembly, then the clutch cable inspection cover. Fig. 2 Clutch Cable Removal 2. Pull back on clutch cable housing and disengage cable from housing. Fig. 3 Clutch Cable End Separation From Pedal Assembly 3. Disconnect clutch cable up-stop/spacer with cable strand. Depressing the clutch pedal provides access to clutch cable strand. 4. Disconnect cable up-stop/spacer from pedal pivot by wedging a suitable flat blade pry tool between pin and retaining tab. 5. Hold tab slightly away from pin, then pull the up-stop/spacer off pedal. 6. Remove cable end from up-stop/spacer. 7. Reverse procedure to install. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications Fluid - Differential: Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ........................................................ 0.9L (1.9 Pints) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service Precautions Axle Shaft: Service Precautions CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the interconnecting shaft where the cross is installed. This twist causes a interference fit between the interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting shaft. This design eliminates the clearance between the cross and the interconnecting shaft resulting in quieter operation of the driveshaft assembly. This design though, eliminated the capability of removing the outer C/V joint from the interconnecting shaft. For this reason the driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft and vibration damper) in the event of a outer C/V joint boot failure. The inner joint sealing boot will be serviced, as on past applications, as a separate component of the driveshaft assembly. CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the C/V joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends, can cut boots or damage C/V joints. During removal and installation procedures, always support both ends of the driveshaft to prevent damage. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service Precautions > Page 4337 Axle Shaft: Description and Operation DESCRIPTION Vehicles equipped with either an automatic or manual transmission uses an unequal length driveshaft system. Vehicles equipped with automatic transaxles use a solid short interconnecting shaft on the left side. The right side of the vehicle uses a longer solid interconnecting shaft. Driveshafts used on both the right and left sides of the vehicle use a tuned rubber damper weight. The damper weight on the right side is a single clamp style damper. The damper weight on the left side is a double clamp style damper. When replacing a driveshaft, be sure the replacement driveshaft has the same damper weight as the original. Both driveshaft assemblies use the same type of inner and outer joints. The inner joint of both driveshaft assemblies is a tripod joint, and the outer joint of both driveshaft assemblies is a Rzeppa joint. Both tripod joints and Rzeppa joints are true Constant Velocity (C/V) joint assemblies. The inner tripod joint allows for the changes in driveshaft length through the jounce and rebound travel of the front suspension. On vehicles equipped with ABS brakes, the outer C/V joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both driveshafts is splined into the transaxle side gears. The inner tripod joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of the tripod joint. The outer C/V joint has a stub shaft that is splined into the wheel hub and retained by a hub nut using a nut lock and cotter pin, hub nut retention system. NOTE: This vehicle does not use a rubber lip bearing seal as on past front wheel drive cars, to prevent contamination of the front wheel bearing. On these vehicles, the face of the outer C/V joint has a metal bearing shield which is pressed onto the end of the outer C/V joint housing. This design deters direct water splash on bearing seal while allowing any water that gets in, to run out the bottom of the bearing shield. It is important though to thoroughly clean the outer C/V joint and the wheel bearing area in the steering knuckle before it is assembled after servicing. IDENTIFICATION Driveshafts and driveshaft inner and outer boots can be identified as shown. Driveshaft boot location on the driveshaft assemblies, is determined by the number of convolutes used on the driveshaft boot. Refer to image for the correct location of the sealing boots. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service Precautions > Page 4338 Axle Shaft: Testing and Inspection LEAKAGE INSPECTION 1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. 2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: 1. Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. 2. Noise may also be caused by another component of the vehicle coming in contact with the driveshafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: 1. A torn seal boot on the inner or outer joint of the driveshaft assembly. 2. A loose or missing clamp on the inner or outer joint of the driveshaft assembly. 3. A damaged or worn driveshaft C/V joint. SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: 1. A worn or damaged driveshaft inner tripod joint. 2. A sticking tripod joint spider assembly (inner tripod joint only). 3. Improper wheel alignment. See Wheel Alignment in this group for alignment checking and setting procedures and specifications. VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: 1. Foreign material (mud, etc.) packed on the backside of the wheel(s). 2. Out of balance front tires or wheels. 3. Improper tire and/or wheel runout. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal Axle Shaft: Service and Repair Removal CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 203 Nm (150 ft.lbs.)244 Nm (180 ft. lbs.). This will ensure that the hub bearing cannot loosen. 1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle. 2. Loosen (but do not remove) stub axle to hub/ bearing retaining nut. Loosen hub nut while vehicle is on the floor with the brakes applied. The front hub and driveshaft are splined together and retained by the hub nut. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Remove front tire and wheel assembly from the hub. 5. Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4341 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. 7. Support brake caliper/adapter assembly using a wire hook. Do not support assembly by the brake flex hose. 8. Remove braking disc from front hub. 9. Remove nut attaching outer tie rod end to steering knuckle. Remove nut from tie rod end by holding tie rod end stud with a 11/32 socket and loosen and remove nut. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4342 10. Remove the tie rod end stud from steering knuckle arm, using remover, Special Tool MB-991113, or equivalent. Fig. 6 11. If equipped with antilock brakes, remove the speed sensor cable routing bracket from the steering knuckle. 12. Remove cotter pin and castle nut from stud of lower ball joint at the steering knuckle. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 13. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4343 13. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike steering knuckle boss until steering knuckle separates from stud of lower ball joint. When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal. NOTE: Care must be taken not to separate the inner ON joint during this operation. Do not allow driveshaft to hang by inner ON joint. Driveshaft must be supported. 14. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly. CAUTION: When inserting pry bar between inner tripod joint and transaxle case, care must be used to ensure no damage occurs to oil seal in transaxle case. 15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and transaxle case. Pry against inner tripod joint, until tripod joint retaining snap ring is disengaged from transaxle side gear. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4344 16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft. lbs.). This will ensure that the hub bearing cannot loosen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4345 Axle Shaft: Service and Repair Installation 1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand. 3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand. 4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be installed into steering knuckle. 5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C/V joint into hub and bearing assembly. 6. Slide driveshaft back into front hub. Then install steering knuckle onto the lower control arm ball joint stud. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4346 7. Install the steering knuckle to ball joint stud castle nut. Tighten the castle nut to 95 Nm (70 ft. lbs.). Fig. 6 8. If equipped with antilock brakes, install the speed sensor cable on the steering knuckle and securely tighten bolt. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4347 9. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle nut. Using a crowfoot and 11/32 socket, tighten the nut to 61 Nm (45 ft. lbs.). 10. Install braking disc back on hub and bearing assembly. 11. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 12. Install caliper assembly to steering knuckle guide pin bolts. Tighten caliper assembly bolts to 31 Nm (23 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4348 13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto threads of stub axle and tighten nut. 14. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 203 Nm (150 ft. lbs.) to 244 Nm (180 ft. lbs.). 15. Install the spring washer, hub nut lock, and new cotter pin on end of stub axle. Wrap cotter pin prongs tightly around the hub nut lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4349 16. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in the correct sequence. Tighten lug nuts to 135 Nm (100 ft. lbs.). 17. Lower vehicle. 18. Check for correct fluid level in transaxle assembly. 19. Set front toe on vehicle to required specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 4350 Axle Shaft: Service and Repair Overhaul CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the interconnecting shaft where the cross is installed. This twist causes a interference fit between the interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting shaft. This design eliminates the clearance between the cross and the interconnecting shaft resulting in quieter operation of the driveshaft assembly. This design though eliminated the capability of removing the outer C/V joint from the interconnecting shaft. For this reason the driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft and vibration damper) in the event of a outer C/V joint boot failure. NOTE: The only service which is to be performed on the driveshaft assemblies is the replacement of the driveshaft seal boots on the inner tripod joints. If any failure of internal driveshaft components is diagnosed during a vehicle road test or disassembly of the driveshaft, the driveshaft will need to be replaced as an assembly. CAUTION: Lubricant requirements and quantities are different for inner joints than for outer joints. Use only the recommended lubricants in the required quantities when servicing driveshaft assemblies. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 4351 Axle Shaft: Tools and Equipment Bearing Shield Installer C-4698 Tie Rod Remover MB-990635 Boot Clamp Installer C-4975A Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Constant Velocity Joint Boot: Service and Repair Inner Tripod Joint Removal NOTE: To remove sealing boots from driveshafts, the driveshaft assemblies must be removed from the vehicle. The inner tripod joints use no internal retention in the tripod housing to keep the spider assembly in the housing. Therefore, do not pull on the interconnecting shaft to disengage tripod housing from transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing boots. 1. Remove the driveshaft requiring boot replacement from the vehicle. 2. Remove large boot clamp which retains inner tripod joint sealing boot to tripod joint housing and discard. Remove small clamp which retains inner tripod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the tripod joint housing from the spider assembly, hold the bearings in place on the spider bunions to prevent the bearings from falling away. 3. Slide the tripod joint housing off the spider assembly and the interconnecting shaft. 4. Remove snap ring which retains spider assembly to interconnecting shaft. Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift. Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint > Page 4356 5. Slide sealing boot off interconnecting shaft. 6. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft assemblies are not serviceable. Installation NOTE: The inner tripod joint sealing boots are made from two different types of material. High temperature applications use silicone rubber where as standard temperature applications use hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot which was removed. PROCEDURE 1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then, slide the replacement inner tripod joint sealing boot onto the interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint > Page 4357 2. Install spider assembly onto interconnecting shaft. Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift. Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. 3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of interconnecting shaft. Be sure the snap ring is fully seated into groove on interconnecting shaft. 4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. 5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft. 6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint > Page 4358 7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C- 4975-A over bridge of clamp. Tighten nut on crimping tool C- 4975-A, or equivalents until jaws on tool are closed completely together, face to face. CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. CAUTIONS: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing sealing boot durability can be adversely affected. - When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot can not be used. 9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly. When inserting trim stick between tripod housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing. If this is not done damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint > Page 4359 the hard plastic sealing boot and soft rubber insert. 10. With trim stick inserted between sealing boot and tripod joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint housing. This procedure will equalize the air pressure in the tripod joint, preventing premature sealing boot failure. 11. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recess's of the tripod housing. 12. Clamp tripod joint sealing boot to tripod joint, using required procedure for type of boot clamp application. Crimp Type Boot Clamp If seal boot uses crimp type boot clamp: Clamp sealing boot onto tripod housing using Crimper, Special Tool C-4975-A, or equivalents. - Place crimping tool C- 4975-A, or equivalent over bridge of clamp. - Tighten nut on crimping tool C- 4975-A, or equivalent until jaws on tool are closed completely together, face to face. Latching Type Boot Clamp If seal boot uses low profile latching type boot clamp: Clamp sealing boot onto tripod housing using clamp locking tool, Snap-On YA3050 or an equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint > Page 4360 - Place prongs of clamp locking tool in the holes of the clamp. - Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp. 13. Install the driveshaft back on the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint > Page 4361 Constant Velocity Joint Boot: Service and Repair Outer CV Joint CAUTIONS: - The outer C/V joint used on this vehicle is not a serviceable joint. - The outer C/V joint used on this vehicle uses a new design for retaining the cross to the interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the interconnecting shaft where the cross is installed. This twist causes a interference fit between the interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting shaft. This design eliminates the clearance between the cross and the interconnecting shaft resulting in quieter operation of the driveshaft assembly. This design though eliminated the capability of removing the outer C/V joint from the interconnecting shaft. For this reason the driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft and vibration damper) in the event of a outer C/V joint boot failure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint > Page 4362 Constant Velocity Joint Boot: Service and Repair Outer CV Joint Bearing Shield NOTES: - The front hub/bearing shield on the outer C/V joint is a serviceable component of the outer C/V. If it is damaged in use on a vehicle or during servicing of a driveshaft it can be replaced using the following procedure. - To remove the bearing shield from the outer C/V joint, the driveshaft assemblies must be removed from the vehicle. REMOVAL 1. Clamp driveshaft in a vise by the interconnecting shaft. 2. Using a drift tap around the entire edge of the bearing shield until it is removed from the outer C/V Joint. INSTALLATION 1. Install bearing shield by hand on outer C/V Joint so that it is installed squarely on the C/V joint. 2. Position installer, Special Tool, C-4698-2 and handle, Special Tool, C-4698-1, or equivalent on face of bearing shield. CAUTION: If bearing shield is not installed flush against the face of the outer C/V joint, interference with Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint > Page 4363 3. Using a hammer, drive the bearing shield on the outer C/V joint until it is flush against the front of the outer C/V joint. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Tighten front axle shaft stub to ...................................................................................................................... 203 Nm (150 ft. lbs) to 244 Nm (180 ft. lbs.) Tighten Rear Hub/Bearing Assembly Retaining Nut ............................................................................................................................ 250 Nm (185 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 4368 Wheel Bearing: Fluid Type Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4369 Wheel Bearing: Description and Operation All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. However, if servicing of a rear wheel bearing is required, refer to procedures in Testing and Inspection and Service and Repair for the inspection and replacement of the rear wheel bearing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4370 Wheel Bearing: Testing and Inspection The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4371 Wheel Bearing: Service and Repair REMOVE 1. Raise vehicle on jackstands or center on a frame contact type hoist. 2. Remove rear wheel and tire assembly. Rear Brake Drum Removal 3. Remove brake drum from rear hub/ bearing assembly. Rear Hub/Bearing Dust Cap 4. Remove dust cap from rear hub/bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4372 5. Remove hub/bearing assembly to rear spindle retaining nut. 6. Remove rear hub/bearing assembly from spindle. Hub/bearing is removed by pulling it straight off the spindle by hand. INSTALL 1. Install the hub/bearing assembly on the knuckle. Then install a NEW rear hub/bearing assembly retaining nut. Tighten the hub/ bearing assembly retaining nut to a torque of 250 Nm (185 ft. lbs.). 2. Install hub/bearing assembly dust cap, using a soft faced hammer. 3. Install brake drum on rear hub/bearing assembly. 4. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in criss cross pattern to one-half the specified torque. Then repeat pattern, fully tightening the stud nuts to a torque of 109 - 150 Nm (80 - 110 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Tightening 1995-96 Stratus/Cirrus/Breeze .............................................................................................................................................244 Nm (180 ft. lbs.) Tightening 1997 Stratus/Cirrus/Breeze ........................................................................................................... 203 Nm (150 ft. lbs.) to 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Drive Plate to Crankshaft Bolts 70 ft.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications To Crankshaft Bolts ............................................................................................................................. ..................................................... 95 Nm (70 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION PRNDL (Electronic) On vehicles equipped with an automatic transmission an electronic PRNDL is used to indicate to the operator gearshift position. When the ignition switch is in the OFF (unlock), RUN, or START position the Body Control Module (BCM) transmits a message over the CCD Bus instructing the instrument cluster to illuminate the proper display The BCM receives its information over the CCD Bus from the Transmission Control Module (TCM). When the ignition switch is moved to the RUN position, the BCM instructs the instrument cluster to illuminate all segments of the PRNDL as a check. PRNDL Illumination The PRNDL illumination is handled by a Light Emitting Diode (LED) and receives power on the E2 circuit from the Body Control Module (BCM). This circuit is HOT when the operator has turned the headlamp switch to the PARK or ON position. Lamp intensity is controlled by the input of the dimmer switch to the BCM on circuit E19. Ground for the LED is provided by the Z1 circuit. This circuit terminates at the instrument panel left side cowl after passing through the ground joint in the junction block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb Shift Indicator: Service and Repair Floor PRNDL Bezel Lamp Bulb The floor PRNDL bezel lamp has no service able bulb. If the lamp does not function properly, the PRNDL bezel assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb > Page 4390 Shift Indicator: Service and Repair Floor PRNDL Lamp REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of PRNDL bezel from floor console. 3. Pull upward carefully on PRNDL bezel and disengage tabs from rear floor console bezel. 4. Disengage wire connector to lamp assembly. 5. Separate PRNDL bezel and lamp assembly from vehicle. INSTALLATION 1. Position PRNDL and lamp assembly to vehicle. 2. Engage wire connector to lamp assembly. 3. Engage tabs on PRNDL bezel to slots in rear floor console bezel. 4. Push downward on PRNDL bezel to engage to bezel to floor console. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator Transmission Mode Indicator - A/T: Service and Repair Odometer/Transmission Range Indicator REMOVAL 1. Remove speedometer/tachometer. Odometer/Transmision Range Indicator 2. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 4395 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 4396 Odometer/Transmision Range Indicator 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ............................................. 1.9-2.2L (4.0-4.6 Pints) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4402 Fluid - M/T: Fluid Type Specifications NV T350 .............................................................................................................................................. ........................................................... 2.1 L (2.2 qts.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Gearshift Service - Mandatory Battery Disconnecting Shift Cable: Technical Service Bulletins Gearshift Service - Mandatory Battery Disconnecting NO: 21-16-96 GROUP: Transmission DATE: Nov. 15, 1996 SUBJECT: Gearshift Service/ Battery Disconnect MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus 1996 - 1997 (JX) Sebring Convertible DISCUSSION: The Airbag Control Module (ACM) is located in the floor console near the transmission gearshift linkage. Any sudden impact or vibration near the ACM with the key in the run position may cause airbag deployment. In order to prevent possible airbag deployment during the following gearshift related service procedures, the battery must be disconnected: ^ Gearshift cable adjustment ^ Gearshift cable replacement ^ Shifter ignition interlock cable adjustment ^ Shifter ignition interlock cable replacement ^ Gearshift mechanism replacement POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Page 4408 Shift Cable: Service and Repair NOTE: Use this procedure if either of the shift cables require replacement. REMOVAL AND INSTALLATION 1. Disconnect Power Distribution Center from battery tray and set aside. 2. Remove air cleaner inlet horn. 3. Remove battery and battery tray. Shift Cable Removal 4. Disconnect gear shift cable ends from transaxle shift levers. CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. 5. Remove cable to bracket retaining clips at transaxle. CAUTION: It is recommended that new cable retaining clips be used for reinstallation. 6. Pull cables up out of transaxle bracket. 7. Remove console from vehicle. Cable Retaining Clips 8. Remove floor pan grommet retaining nuts. 9. Remove cable retaining clips at shifter. CAUTION: It is recommended that new cable retaining clips be used for reinstallation. 10. Disconnect shift cables from shifter. Pry with equal force on both sides of shifter cable isolator bushings to avoid damaging bushings. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Technical Service Bulletins > Page 4409 Shift Cable Floor Grommet 11. Lift vehicle on hoist. Remove self tapping screws securing grommet plate to underbody heat shield and floor pan. 12. Detach cables from cable support clip in tunnel above exhaust catalyst. 13. Remove shift cables from vehicle. To install, reverse removal procedure. After cables have been replaced, cable adjustment should be checked. CAUTION: Only the crossover cable is adjustable. The selector cable does not have any adjustment capabilities. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 4420 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 4421 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 4427 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 4428 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4431 Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4432 Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4433 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4434 Fuse Block PCM Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4435 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4438 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4439 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4440 Part 2 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4441 Part 3 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4442 Part 4 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4443 Part 5 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4444 Part 6 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4445 Part 7 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4446 Part 8 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4447 Part 9 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4448 Part 11 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4451 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4452 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4453 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4454 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4455 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4456 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4457 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4458 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4459 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4460 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4461 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4462 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4463 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, 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 over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4464 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4467 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4471 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4472 Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Autostick Switch Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 4478 Autostick Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4487 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4488 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4489 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4495 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4496 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4501 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4502 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4503 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4509 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4510 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4511 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4514 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4515 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4516 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4517 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4518 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4527 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4532 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4533 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4534 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4540 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4545 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4546 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4547 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4548 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4549 Input / Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4552 Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4553 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Locations > Page 4563 Transmission Solenoid Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION PRNDL (Electronic) On vehicles equipped with an automatic transmission an electronic PRNDL is used to indicate to the operator gearshift position. When the ignition switch is in the OFF (unlock), RUN, or START position the Body Control Module (BCM) transmits a message over the CCD Bus instructing the instrument cluster to illuminate the proper display The BCM receives its information over the CCD Bus from the Transmission Control Module (TCM). When the ignition switch is moved to the RUN position, the BCM instructs the instrument cluster to illuminate all segments of the PRNDL as a check. PRNDL Illumination The PRNDL illumination is handled by a Light Emitting Diode (LED) and receives power on the E2 circuit from the Body Control Module (BCM). This circuit is HOT when the operator has turned the headlamp switch to the PARK or ON position. Lamp intensity is controlled by the input of the dimmer switch to the BCM on circuit E19. Ground for the LED is provided by the Z1 circuit. This circuit terminates at the instrument panel left side cowl after passing through the ground joint in the junction block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb Shift Indicator: Service and Repair Floor PRNDL Bezel Lamp Bulb The floor PRNDL bezel lamp has no service able bulb. If the lamp does not function properly, the PRNDL bezel assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb > Page 4571 Shift Indicator: Service and Repair Floor PRNDL Lamp REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of PRNDL bezel from floor console. 3. Pull upward carefully on PRNDL bezel and disengage tabs from rear floor console bezel. 4. Disengage wire connector to lamp assembly. 5. Separate PRNDL bezel and lamp assembly from vehicle. INSTALLATION 1. Position PRNDL and lamp assembly to vehicle. 2. Engage wire connector to lamp assembly. 3. Engage tabs on PRNDL bezel to slots in rear floor console bezel. 4. Push downward on PRNDL bezel to engage to bezel to floor console. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator Transmission Mode Indicator - A/T: Service and Repair Odometer/Transmission Range Indicator REMOVAL 1. Remove speedometer/tachometer. Odometer/Transmision Range Indicator 2. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 4576 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 4577 Odometer/Transmision Range Indicator 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 4588 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 for Control Module: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 4589 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift Technical Service Bulletin # 21-02-98A Date: 980606 A/T - Shudder on 1 - 2/2 - 3 Upshift NO.: 21-02-98 Rev.A GROUP: Transmission DATE: Jun. 26, 1998 SUBJECT: Diagnostic/Driveability Improvements, Transaxle Desensitization To Intermittent Faults, **1-2 Shudder Fix** THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-98, DATED FEB. 13, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES NEW SOFTWARE TO ADDRESS NS/GS LIGHT TO MEDIUM 1-2 UPSHIFT SHUDDER ISSUES ALONG WITH ADDITIONAL INFORMATION. MODELS: 1996 - 1997 (FJ) Avenger/Sebring/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1996 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1996 - 1997 (LH) Concorde/Intrepid 1996 - 1997 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES WITH A 41TE/AE OR 42LE TRANSAXLE THAT INCORPORATES A TRANSMISSION RANGE SENSOR (TRS) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Discussion New software has been released to address the following: **On NS/GS models:** 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. **Replacement of 2-4 clutch components listed in TSB 21-11-96 Rev. A, should not be required.** 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. All models: 1. Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: A. Begins in 2nd gear **(super cold shift schedule)** and does not shift until after a few minutes of driving. Possibly caused by **an intermittent** thermistor circuit fault. A thermistor circuit that is in range electrically but falsely showing a temperature that is very cold, or very hot will cause the TCM to use modified shift schedules based on the temperature (ie. extreme cold - only 2nd gear and reverse, supercold - delayed shifts etc., or overheat - delayed shifts etc.). **It is important to note that the thermistor, input speed, and output speed sensors share a common ground. Problems in one circuit may affect the others.** DTC 74 - CALCULATED TEMPERATURE IN USE may or may not be set. The new software will ignore the thermistor reading if not Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 4595 close to the calculated oil temperature at start-up. The "TRANS TEMP DEG" and "TRANS TEMP STATE" seen on the DRB Ill may be derived from either the thermistor value or calculated oil temperature depending on fault or no fault conditions. To read the thermistor value for diagnostic purposes, use "TRANS TEMP VOLTAGE" on the DRB III with the engine running. This will give the actual thermistor value in volts and can be used to decide if the thermistor circuit is at fault. If the thermistor circuit is out of range, always check to make sure the electrical connections are corrosion/contamination free when performing diagnostics. B. All PRNDL lights on with or without DTC 28 - CHECK SHIFTER SIGNAL. Possibly caused by a TRS circuit fault. C. When shifter is moved between the 2/3 or L positions, transaxle stays in original position until driver shifts to OD/D or to N then back to OD/D. Possibly caused by a TRS circuit fault. D. Intermittent limp-in (stuck in second gear) with pressure switch, speed sensor, or gear ratio DTC's. The new software will set the DTC when the fault is identified, but will not cause a limp-in condition until the fault has occurred several times. 2. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. 3. Includes capability to set new/improved DTC's (ie. DTC 76 - POWER UP AT SPEED etc.) and make use of the latest diagnostic tests listed in the 41TE/AE diagnostic manual (p/n 81-699-97148) and 42LE diagnostic manual (pin 81-699-97031). On FJ 2.0L (non turbo) models: 1. Uses the 97 shift schedules on 96 model vehicles. Enhances mid throttle performance. On 96/97 3.5L LH models: 1. Reduces engine surge during full EMCC application by raising its application from 41 mph to 47 mph. NOTE: VEHICLES THAT EXHIBIT THIS CONDITION MUST HAVE THE POWERTRAIN CONTROL MODULE FLASHED. **SEE TSB 18-15-98 FOR 96197 3.5L LH LIGHT SURGE BETWEEN 42 AND 50 MPH FOR MORE DETAILS.** Diagnosis Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. Equipment/Parts Required 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (OPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1161** OR HIGHER MUST BE INSTALLED. Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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: > 21-02-98A > Jun > 98 > A/T - Shudder on 1 - 2/2 - 3 Upshift > Page 4596 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 VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III(R) 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 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4599 Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4600 Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4601 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4602 Fuse Block PCM Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4603 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module Power Control Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4606 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4607 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4608 Part 2 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4609 Part 3 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4610 Part 4 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4611 Part 5 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4612 Part 6 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4613 Part 7 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4614 Part 8 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4615 Part 9 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Power Control Module > Page 4616 Part 11 Of 11 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4619 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4620 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4621 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4622 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4623 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4624 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4625 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4626 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4627 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4628 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4629 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4630 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4631 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, 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 over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4632 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4635 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4639 Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4640 Transmission Control Relay Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Locations Autostick Switch Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Locations > Page 4646 Autostick Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4655 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4656 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4657 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4663 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4664 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4669 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4670 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4671 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4677 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4678 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4679 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4682 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4683 Transmission Range Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4684 Transmission Position Switch/Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4685 Transmission Position Switch/Sensor: Service and Repair 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 > Page 4686 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4695 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4700 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4701 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4702 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4708 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4713 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4714 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4715 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4716 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4717 Input / Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4720 Output Speed Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 4721 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Service Precautions ABS Light: Service Precautions NOTE: When the Controller Antilock Brake (CAB) detects a non-functional Amber Antilock Brake System (ABS) Warning and a ABS fault is also detected at the same time which results in shutting down the ABS Brakes, then the CAB will turn on the Red Brake Warning Lamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Service Precautions > Page 4730 ABS Light: Description and Operation ANTILOCK BRAKE SYSTEM (ABS) AMBER WARNING LAMP The ABS system uses an Amber ABS Warning Lamp, located in the instrument cluster. The purpose of the warning lamp is discussed in detail below. When Detection Occurs The ABS warning lamp will turn on when the Controller Antilock Brake (CAB) detects a condition which results in a shutdown of ABS function. The ABS Warning Lamp is normally on until the CAB completes its self tests and turns the lamp off (approximately 4-5 seconds after the ignition switch is turned on). When the ABS warning lamp is on, only the ABS function of the brake system if affected. The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations System Relay And Pump Motor Relay Box Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Description and Operation > ABS System Relay ABS Main Relay: Description and Operation ABS System Relay CIRCUIT OPERATION The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor, and terminates at the right frame rail. when the system is operating normally, power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the right frame rail. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the A20 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Description and Operation > ABS System Relay > Page 4736 ABS Main Relay: Description and Operation ABS System Relays System Relay And Pump Motor Relay Box SYSTEM RELAY The main purpose of the system relay is to put the Antilock Brake System (ABS) into a stand-by mode for ABS operation. The System Relay is energized by the Controller Antilock Brake (CAB) shortly after the ignition switch is turned on. When Energized - by the CAB, the System Relay turns off the ABS warning lamp and provides 12 volts to the CAB. This voltage can then be used by the CAB to energize the Decay Solenoids during ABS braking. When energized, the System Relay also provides the Pump/Motor Relay coil with 12 volts. The ground path to the Pump/Motor Relay is completed by the CAB during ABS braking. When De-energized - the ABS warning lamp is illuminated, voltage to the Decay Solenoids is cut off, and the Pump/Motor Relay is prevented from energizing. Typically, the System Relay is de-energized by the CAB when a fault is detected that requires turning ABS off. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations System Relay And Pump Motor Relay Box Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Locations > Page 4740 Brake Fluid Pump: Description and Operation HYDRAULIC CONTROL UNIT (HCU) PUMP MOTOR ASSEMBLY The HCU contains 2 Pump Assemblies, one each for the primary and secondary hydraulic circuits. Both pumps are driven by a common electric motor which is part of the Hydraulic Control Unit (HCU). The pumps pick up fluid from the sumps to supply build pressure to the brakes during an Antilock Brake System (ABS) stop. The motor only runs during an ABS stop and is controlled by the Controller Antilock Brakes (CAB) via the Pump/Motor Relay. The Pump/Motor Assembly is not a serviceable item. If it requires service the HCU must be replaced. For additional information See: Hydraulic Control Unit Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Description and Operation > Description Brake Fluid Pump Relay: Description and Operation Description System Relay And Pump Motor Relay Box PURPOSE Pump/Motor power is supplied by the Pump/Motor Relay. The pump motor relay is also part of the relay box mounted to the Hydraulic Control Unit (HCU). If pump/motor relay replacement is required, it is also only serviced by the replacement of the relay box assembly. FUNCTION Voltage for the 12 volt side of the relay coil is provided by the System Relay. The ground path through the relay coil is completed by the Controller Antilock Brake (CAB) during Antilock Brake System (ABS) braking. The relay contacts are closed when the relay is energized. This provides 12 volts to the pump/motor as needed during ABS braking. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Description and Operation > Description > Page 4745 Brake Fluid Pump Relay: Description and Operation Circuit Operation CIRCUIT OPERATION The ABS pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B120 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B10 from the relay box powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations System Diagnostic Connector Location On this vehicle, the ABX-4 diagnostic connector is located under the lower instrument panel directly next to the left kick panel. The ABX-4 system uses the ISO 9141-K connector which is shared by other vehicle diagnostic systems such as the power-train control module and air bag. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 4752 Diagnostic Connector - ABS: Description and Operation CIRCUIT OPERATION Circuit D21 is used for diagnostics of a fault within the ABS system. It is spliced in with the Powertrain Control Module (PCM) circuits, and is used as an output from the Controller Anti-Lock Brake (CAB). Circuit D21 connects to cavity 51 of the CAB connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 4753 Diagnostic Connector - ABS: Testing and Inspection - Check the 10 amp fuse located in cavity 10 of the PDC - Check the 40 amp fuse located in cavity 13 of the PDC - Check the 20 amp fuse located in cavity 2 of the PDC - Check for a good ground at the right frame rail - Check the case ground on the CAB Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Controller Antilock Brake Location CAB 60-Way Wiring Harness Connector The CAB is located in the right front corner of the engine compartment. It is mounted to the vehicle using an integral mounting bracket, which is attached by 2 bolts, to the inner fender and the front crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4757 Electronic Brake Control Module: Description and Operation Controller Antilock Brake Location PURPOSE The Controller Antilock Brakes (CAB) is a microprocessor based device which monitors the ABS system during normal braking and controls it when in an ABS stop. The CAB is mounted in the right front corner of the engine compartment using an integral mounting bracket to attach it to the inner fender. The CAB uses a 60 way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the Run or ON position. NOTE: The CAB is not on the Chrysler Collision Detection (CCD) bus. THE PRIMARY FUNCTIONS OF THE CAB - Detect wheel locking tendencies. - Control fluid modulation to the brakes while in ABS mode. - Monitor the system for proper operation. - Provide communication to the DRB scan tool while in diagnostic mode. The CAB Continuously Monitors - the speed of each wheel through the signals generated at the Wheel Speed Sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABS System Is Constantly Monitored - by the CAB for proper operation. If the CAB detects a fault, it will turn on the Amber ABS Warning Lamp and disable the ABS braking system. The normal Non ABS braking system will remain operational. The CAB Contains A Self-diagnostic Program - which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected. Faults are then stored in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB and displayed through the DRB scan tool. These fault messages will remain in the CAB memory even after the ignition has been turned off. The fault messages can be cleared by using the DRB scan tool, or they will be automatically cleared from the memory after a minimum of 3500 vehicle miles are accumulated. CONTROLLER ANTILOCK BRAKE INPUTS - Four wheel speed sensors. - Stop lamp switch. - Ignition switch. - System relay voltage. - Ground. - Pump/Motor Relay Monitor. - Diagnostics Communications. CONTROLLER ANTILOCK BRAKE OUTPUTS - Decay Solenoids. - ABS warning lamp. - System relay actuation. - Diagnostic communication (Single line ISOK). - Pump motor relay actuation. - Brake Lamp (Low Fluid/Pressure). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4758 Electronic Brake Control Module: Service and Repair Controller Antilock Brake Location REMOVE 1. Turn vehicle ignition off. CAB 60-Way Wiring Harness Connector 2. Disconnect the wiring harness 60 way connector from the Controller Antilock Brake Module (CAB). Verify that the vehicle ignition is off before removing the 60 way connector. CAB Bracket To Engine Compartment Mounting 3. Remove the 2 bolts attaching the CAB mounting bracket to inner fender and front upper crossmember. 4. Remove the CAB from the vehicle. INSTALL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4759 1. Install the CAB and the mounting bracket assembled, on the right inner fender of the vehicle. 2. Install the 2 bolts mounting the CAB bracket to the vehicle. Tighten both mounting bolts to a torque of 9 Nm (75 inch lbs.). 3. Install 60-way wiring harness connector into the CAB 60-way connector by hand until seated as far as possible. Then use CAB connector retaining bolt to fully seat wiring harness connector into the CAB. 4. Tighten the 60-way connector retaining bolt to a torque of 4 Nm (35 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications Hydraulic Control Unit: Specifications To Mounting Bracket Bolts .................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Bracket To Crossmember Mounting Bolts .......................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications > Page 4763 Hydraulic Control Unit Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications > Page 4764 Hydraulic Control Unit: Service Precautions WARNING: THE ONLY PARTS OF THE HYDRAULIC CONTROL UNIT (HCU) THAT ARE SERVICEABLE ARE THE RELAY BOX, THE PROPORTIONING VALVES, AND THE HCU MOUNTING BRACKET. THE REMAINING COMPONENTS OF THE HYDRAULIC CONTROL UNIT HCU ARE NOT SERVICEABLE ITEMS. NO ATTEMPT SHOULD EVER BE MADE TO REMOVE OR SERVICE ANY OTHER PARTS OF THE HYDRAULIC CONTROL UNIT HCU. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information Hydraulic Control Unit: Description and Operation General Information Hydraulic Control Unit PURPOSE The Hydraulic Control Unit (HCU) is located on the right side of the vehicle, mounted to the front suspension. The HCU is mounted to the front suspension crossmember using a mounting bracket attached to the crossmember, which the HCU is mounted to using 3 isolation bushings. The HCU contains the following components for controlling brakes during Antilock Brake System (ABS) braking: 4 Decay Valves, 4 Shuttle Valves, 2 Fluid Sumps, a Pump/Motor and a relay box. Also attached to the HCU are the rear brake Proportioning Valves and the vehicles 6 hydraulic brake tubes. Decay Solenoids There are 4 decay solenoids, one for each wheel. In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle. In the actuated (decay) position, they provide a fluid path from wheel brakes of the vehicle to the sumps. The Decay solenoids are spring loaded in the released (build) position during normal braking. Shuttle Valves There are 4 Shuttle Valves, one for each wheel. The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized. This places an orifice (restriction) in the line between the pump and the decay solenoid. This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the ABS cycle is complete. When the ABS cycle has been completed the decay solenoids will return to their released position which will equalize the pressure across the Shuttle Valves. When the pressure equalizes, the spring loaded Shuttle Orifice valves will return to the unrestricted position. Fluid Sumps There are two fluid sumps in the HCU, one each for the primary and secondary hydraulic circuits. The fluid sumps temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This fluid is then delivered to the pump to provide build pressure. The typical pressure in the sumps is 50 psi, during ABS operation only. Pump Motor Assembly The HCU contains 2 Pump Assemblies, one each for the primary and secondary hydraulic circuits. Both pumps are driven by a common electric motor which is part of the HCU. The pumps pick up fluid from the sumps to supply build pressure to the brakes during an ABS stop. The motor only runs during an ABS stop and is controlled by the Controller Antilock Brake (CAB) via the Pump/Motor Relay. The Pump/Motor Assembly is not a serviceable item. If it requires service the HCU must be replaced. Relay Box ABX-4 utilizes two relays contained in a relay box mounted to the HCU. The relay box contains a System Relay and a Pump/Motor Relay. A single 10-way connector provides the electrical interface. The relay box is serviceable as an assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4767 Hydraulic Control Unit: Description and Operation Hydraulic Control Unit Decay Solenoids HYDRAULIC CONTROL UNIT DECAY SOLENOIDS There are 4 decay solenoids, one for each wheel. In the released position they provide a fluid path from the Master Cylinder to the wheel brakes of the vehicle. In the actuated (decay) position, they provide a fluid path from wheel brakes of the vehicle to the sumps. The Decay Solenoids are spring loaded in the released (build) position during normal braking. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4768 Hydraulic Control Unit: Description and Operation Hydraulic Control Unit Shuttle Valves HYDRAULIC CONTROL UNIT SHUTTLE VALVES There are 4 Shuttle Valves, one for each wheel. The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized. This places an orifice (restriction) in the line between the pump and the decay solenoid. This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the ABS cycle is complete. When the ABS cycle has been completed the decay solenoids will return to their released position which will equalize the pressure across the Shuttle Valves. When the pressure equalizes, the spring loaded Shuttle Orifice valves will return to the unrestricted position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4769 Hydraulic Control Unit: Description and Operation Hydraulic Modulator Circuit Operation CIRCUIT OPERATION Hydraulic Modulator The hydraulic modulator is used for controlling the brake system pressure to the wheels. The modulator is composed of four solenoids. Circuits involved are: B142 for the left front wheel, B143 for the right front wheel, B146 for the left rear wheel, and B148 for the right rear wheel. The solenoids use a common ground on the Z1 circuit. There are two Z1 circuits from the modulator. Both of these grounds terminate at the right frame rail, and are spliced in with the ABS pump motor and the ABS system relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement Hydraulic Control Unit: Service and Repair Hydraulic Control Unit (HCU) Replacement Removal PROCEDURE Ground Cable Attachment At Strut Tower 1. Remove the remote ground cable from the ground stud located on the left strut tower. Correctly Isolated Remote Ground Cable 2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown. This will prevent accidental grounding of the remote ground cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4772 Brake Pedal Holding Tool Installed 3. Using a brake pedal positioning tool such as shown depress brake pedal past its first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir. 4. Raise vehicle on jackstands or center on a hoist. 5. Using Mopar, Brake Parts Cleaner or an equivalent, thoroughly clean all surfaces of the Hydraulic Control Unit (HCU). Also, thoroughly clean all brake line tube nut to HCU and proportioning valve connections. Exhaust Pipe Mounting To Exhaust Manifold 6. Remove the entire exhaust system from the vehicle as a complete assembly using following steps. ^ Remove attaching bolts from exhaust pipe at exhaust manifold on engine. Exhaust System Support/Isolators Locations ^ Remove all exhaust system support/isolators from the vehicle's exhaust system. Remove support/isolators from brackets on exhaust system components and leave attached to body of vehicle. ^ Lower exhaust system as a complete assembly away from the underbody of the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4773 Right Side Splash Shield 7. Remove right side engine compartment splash shield from the vehicle. HCU Heat Shield 8. Remove the HCU heat shield from the HCU mounting bracket. Electrical Connections At HCU And Relay Box 9. Disconnect the 6 way connector from the HCU wiring harness and the 10 way connector from the relay box located on the HCU. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4774 Brake Tubes At HCU 10. Remove the brake tube routing clip from the HCU mounting bracket. Then remove the 2 brake tubes coming from master cylinder and the brake tube going to the left front wheel from the HCU ports. Rear Brake Tubes And Right Front Brake Tube At HCU 11. Remove the 2 rear brake tubes from the proportioning valves and the right front brake tube from the outlet port of the HCU. Front Attachment Of HCU To Mounting Bracket 12. Remove bolt attaching the front of the HCU to its mounting bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4775 Rear Attachment Of HCU To Mounting Bracket 13. Remove the 2 bolts attaching the rear of the HCU to its mounting bracket. If vehicle being serviced is equipped with a 2.5L engine, remove the tube as indicated. Removing this tube will make it easier to remove the HCU assembly from the vehicle. Removal Of HCU Assembly From Vehicle 14. Remove HCU from its mounting bracket. Then remove HCU from vehicle out through the exhaust tunnel in the floor pan of the vehicle. Installation PROCEDURE 1. Install the Hydraulic Control Unit (HCU) back in the vehicle and on its mounting bracket using the reverse order of its removal. Rear Attachment Of HCU To Mounting Bracket 2. Install mounting isolators, washers and attaching bolts, mounting the rear of the HCU to the mounting bracket. Do not tighten bolts at this time. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4776 Front Attachment Of HCU To Mounting Bracket 3. Install mounting isolator, washer and attaching bolt, mounting the front of the HCU to the mounting bracket. Do not tighten bolt at this time. 4. Then tighten the 3 HCU mounting bolts to a torque of 28 Nm (248 inch lbs.). Rear Brake Tubes And Right Front Brake Tube At HCU 5. Install the 2 rear brake tubes on the proportioning valves and the right front brake tube in the outlet port of the HCU. Tighten the 3 brake tube nuts to a torque of 20 Nm (180 inch lbs.). Brake Tubes At HCU 6. Install the 2 brake tubes coming from master cylinder and the brake tube to the left front wheel in the HCU ports. Tighten the 3 brake tube nuts to a torque of 20 Nm (180 inch lbs.). Install the brake tube routing clip on the HCU mounting bracket and securely tighten attaching bolt. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4777 Electrical Connections At HCU And Relay Box 7. Install the 6 way connector on the HCU wiring harness and the 10 way connector on the relay box of the HCU. HCU Heat Shield 8. Install the HCU heat shield on the HCU mounting bracket. Install and securely tighten attaching bolt. 9. Install exhaust system in vehicle using the reverse steps of its removal. Right Side Splash Shield 10. Install right side engine compartment splash shield back on the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4778 Ground Cable Attachment At Strut Tower 11. Install the remote ground cable onto the ground stud located on left shock tower. Install the remote ground cable attaching nut and tighten to a torque of 28 Nm (250 inch lbs.). 12. Bleed the base brakes and the ABS brakes hydraulic system. Refer to Antilock Brake System Service and Repair for the proper bleeding procedure. 13. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4779 Hydraulic Control Unit: Service and Repair Relay Box Replacement GENERAL INFORMATION The system relay and pump/motor relay are both serviced together as an assembly with the relay box. The relay box is mounted directly to the Hydraulic Control Unit (HCU). To remove the relay box from the HCU, the HCU requires removal from the vehicle. This is to allow visual access of the relay box to HCU electrical connection. Visual access to this connection is necessary to be sure connection is correctly made when installing the relay box on the HCU. REMOVE 1. Disconnect negative (ground) cable from the battery and isolate the cable. 2. Remove the HCU from the vehicle. Refer to Hydraulic Control Unit Removal, for the required removal procedure for the HCU. Relay Box To HCU Mounting Screws 3. Remove the 2 screws attaching the relay box assembly to the HCU. Remove only the 2 screws mounting the relay box to the HCU. Do not remove the pump motor mounting screws. Relay Box To HCU Electrical Connection 4. Grasp relay box with both hands. Without twisting or rocking, pull relay box away from pump motor housing until connector on relay box unplugs from the pump motor terminal. This is a tight connection, relay box will require a good amount of force to unplug it from the pump motor. 5. Remove relay box from HCU. INSTALL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4780 Pump Motor To Relay Box Electrical Seal 1. Be sure electrical connector seal is installed in pump motor housing before installing relay box. If electrical connector seal is cracked, brittle or in any way damaged it must be replaced before installing relay box. 2. Position relay box on HCU and carefully align the terminals on the relay box with the terminals on the pump motor. 3. Grasp relay box with both hands. Then without twisting or rocking, push relay box onto the pump motor electrical connector as far as possible by hand. 4. Install and securely tighten the 2 screws attaching the relay box assembly to the HCU. 5. Install the HCU back in the vehicle. Refer to Hydraulic Control Unit Installation, for the required installation procedure for the HCU. 6. Connect the negative (-) ground cable back on the negative post of the battery. 7. Bleed the base brakes and the ABS brakes hydraulic system. Refer to the Antilock Brake System Service and Repair for the proper bleeding procedure. 8. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4785 39 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4786 43 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4787 45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4788 47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4789 51 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4790 55 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4791 57 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4792 59 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4793 63 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4794 67 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4795 69 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4796 71 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4797 173 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4798 177 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4799 179 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4800 181 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4801 187 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4802 191 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4803 193 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4804 195 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4805 201 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4806 205 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4807 207 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4808 209 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4809 256 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4810 Wheel Speed Sensor: Specifications Front Rear Clearance Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in Runout 0.006 in 0.006 in Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4811 Wheel Speed Sensor: Service Precautions NOTE: - Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. CAUTION: - If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. - When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4812 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor PURPOSE One Wheel Speed Sensor (WSS) is located at each wheel, and sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a Toothed Sensor Ring (Tone Wheel) passes the stationary magnetic WSS. The CAB converts the AC signal generated at each wheel into a digital signal. OPERATION If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. ASSEMBLY AND LOCATION The front Wheel Speed Sensor is attached to a boss in the steering knuckle. The tone wheel is part of the outboard constant velocity joint. The rear Wheel Speed Sensor on rear drum brake applications is mounted to the rear brake support plate and the rear tone wheel is an integral part of the rear wheel hub and bearing assembly. SERVICE INDIVIDUALLY The four Wheel Speed Sensors are serviced individually. The front Tone Wheels are serviced as an assembly with the outboard constant velocity joint. The rear Tone Wheels are serviced as an assembly with the rear hub and bearing assembly. CORRECT OPERATION DEPENDENT ON ACCURATE SIGNALS Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4813 Wheel Speed Sensor: Testing and Inspection CAREFUL INSPECTION Carefully inspect tone wheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tone wheels should show no evidence of contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive Runout - of the tonewheel can cause erratic wheel speed sensor signals. Refer to Tone-wheel Runout under Specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect For Looseness - on their mounting surfaces. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. See: Specifications Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Removal PROCEDURE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Speed Sensor Cable Routing Brackets 3. Remove the speed sensor cable routing bracket from the steering knuckle. Remove the wiring harness sealing grommet retainer and speed sensor routing bracket from the inner fender. Wheel Speed Sensor Connection To Vehicle Wiring Harness 4. Remove speed sensor sealing grommet from the inner fender. Then unplug the speed sensor cable from the vehicle wiring harness. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4816 Speed Sensor Head Attachment To Steering Knuckle 5. Remove bolt attaching the speed sensor head to the steering knuckle. Then remove speed sensor head from steering knuckle. CAUTION: If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. Speed Sensor Head Removal From Steering Knuckle 6. If speed sensor head can not be removed from steering knuckle by hand, the locating pin on the speed sensor head has seized to the steering knuckle do to corrosion. Remove speed sensor head from steering knuckle using the following procedure. Remove disc brake caliper from steering knuckle, and remove brake rotor from hub/bearing assembly Then insert a pin punch through hole in front steering knuckle and tap speed sensor head locating pin out of steering knuckle. Installation PROCEDURE CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cable, resulting in an open circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4817 Wheel Speed Sensor Connection To Vehicle Wiring Harness 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. Speed Sensor Cable Routing Brackets 2. Install the speed sensor cable assembly grommet into the front inner fender. Install speed sensor cable grommet retainer/routing bracket on the inner fender of the vehicle and install and securely tighten attaching bolt. Correct Front Wheel Speed Sensor Cable Routing CAUTION: When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. 3. Install the speed sensor cable routing bracket on the steering knuckle. Install and tighten routing bracket mounting bolt to a torque of 12 Nm (105 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4818 Installing Speed Sensor Head In Steering Knuckle 4. Install speed sensor head on steering knuckle. When installing speed sensor head on steering knuckle, apply a small amount of grease on speed sensor locating pinch Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pinch Install the speed sensor head attaching screw and tighten to a torque of 6 Nm (55 inch lbs.). 5. Install the wheel and tire assembly on vehicle. 6. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4819 Wheel Speed Sensor: Service and Repair Rear Removal PROCEDURE Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 1. Unplug the speed sensor cable connector from the vehicle wiring harness. Access for speed sensor cable to vehicle wiring harness connection is in the trunk of the vehicle. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove the rear tire and wheel assembly from the vehicle. Rear Speed Sensor Cable Attachment To Body 4. Remove speed sensor cable sealing grommet retainer from the rear frame rail of the vehicle. Then remove speed sensor cable sealing grommet and cable from hole in body of vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4820 Speed Sensor Cable Attachment To Rear Suspension 5. Remove speed sensor routing clips from the rear upper control arm and brake flex hose routing bracket. Rear Speed Sensor Head Attachment To Brake Support Plate 6. Remove the rear speed sensor head from the rear brake support plate. Installation PROCEDURE CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. Rear Speed Sensor Head Attachment To Brake Support Plate 1. Install speed sensor head into brake support plate. 2. Install wheel speed sensor attaching bolt. Tighten the speed sensor head attaching bolt to 8 Nm (75 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4821 Speed Sensor Cable Attachment To Rear Suspension 3. Install speed sensor cable routing clips on the brake flex hose bracket and the bracket on the upper control arm. Install and securely tighten the routing clip attaching bolts. 4. Install connector end of speed sensor cable through hole in inner fender and into trunk of vehicle. Rear Speed Sensor Cable Attachment To Body 5. Install speed control sealing grommet into hole in inner fender. Install the sealing grommet retainer and attaching bolt on rear frame rail. Securely tighten retainer attaching bolt. 6. Install the tire and wheel assembly on vehicle. 7. Lower vehicle. Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 8. Plug speed sensor cable connector into vehicle wiring harness. Install foam sleeve back over the speed sensor cable to vehicle wiring harness connection to prevent connector from rattling against body of vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4822 9. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures GENERAL INFORMATION The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The Antilock Brake System (ABS), particularly the Hydraulic Control Unit (HCU), should only be bled when the HCU is. replaced or removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During Bleeding Operations - be sure that the brake fluid level remains close to the FULL level in the reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The Bendix ABX-4 Brake System must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. Refer to Brakes Service and Repair for the proper bleeding procedure to be used. This brake system can be either pressure bled or manually bled. The ABS portion of brake system MUST be bled separately. This bleeding procedure requires the use of the DRB scan tool and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a Manual bleeding procedure or standard Pressure Bleeding Equipment. If the brake system is to be bled using pressure bleeding equipment, refer to Brakes Service and Repair. 1. Assemble and install all brake system components on vehicle making sure all hydraulic fluid lines are installed and properly torqued. System Diagnostic Connector Location 2. Connect the DRB scan tool to the diagnostics connector. The diagnostics connector is located under the lower instrument panel next to the left kick panel. 3. Using the DRB scan tool, check to make sure the CAB does not have any fault codes stored. If it does, remove them using the DRB scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Brakes Service and Repair. 5. Using the DRB scan tool, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and free of bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brake are operating correctly and that pedal is solid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4827 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Air Trapped In Brake System Method For Purging Air From Brake System Bleeder Screw CAUTION: - Before removing the Master Cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. - Use bleeder tank Special Tool C-3496-B, or equivalent with required adapter for the master cylinder reservoir to pressurize the hydraulic system for bleeding. NOTE: - For bleeding the ABS hydraulic system, refer to Hydraulic Control Unit. - Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. PROCEDURE When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4828 Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The following wheel sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel 1. Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain an steady stream of brake fluid. 3. After 4 to 8 ounces of fluid has been bled through the brake and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder. It must stay at the proper level so air will not be allowed to reenter the brake system through the master cylinder reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 4833 244 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 4834 245 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information Brake Warning Indicator: Description and Operation General Information Master Cylinder Fluid Level Sensor NOTE: If brake fluid level has dropped in master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. GENERAL INFORMATION The red Brake warning lamp is located in the instrument panel cluster and is used to indicate a low brake fluid condition, the parking brake is applied or that the antilock brake system has a fault but could not turn on the yellow ABS warning lamp. In addition, the brake warning lamp is turned on as a bulb check by the ignition switch when the ignition switch is placed in the crank position. Problems with this system will generally be of the type where the warning lamp fails to turn on when it should, or remains on when it should not. CIRCUIT INFORMATION The warning lamp bulb is supplied a 12 volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the park brake switch, the fluid level sensor in the master cylinder reservoir, the ignition switch in the crank position or the ABS Controller Antilock Brake. PURPOSE The Brake Fluid Level sensor is located in the brake fluid reservoir of the master cylinder assembly. The purpose of the sensor is to provide the driver with an early warning that brake fluid level in master cylinder reservoir has dropped to below normal. This may indicate an abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. As the fluid drops below the minimum level, the fluid level sensor closes the brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 4837 Brake Warning Indicator: Description and Operation ABS Warning Lamp Circuit Operation CIRCUIT OPERATION ABS Warning Lamp The ABS warning lamp is an output from the Controller Anti Lock Brake (CAB) and the ABS relay box. It is used to alert the operator of a problem in the ABS system. The G19 circuit from the CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster. Circuit G19 is also an output of the CAB to the ABS system relay contact side. Brake Warning Lamp The brake warning lamp is used to alert the operator of a problem in the vehicles braking system. This lamp also illuminates when the ignition switch is turned to the START position to perform a self check. Power for the lamp is supplied on circuit F11. This circuit is HOT when the ignition switch is in the OFF START, and RUN positions. The F11 circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. There are two switches used in this system and they are wired in parallel form. A parking brake switch, located on the parking brake mechanism, will illuminate the lamp if the normally OPEN switch is CLOSED. This switch is case grounded. The second switch used is the brake warning lamp switch. This switch in normally OPEN. When the brake system pressure is below the predetermined level the switch CLOSES and completes a path to ground. The G9 circuit is used to connect the switches to the cluster. Grounding for the brake warning lamp switch is completed on the Z1 circuit which terminates at the left strut tower. If the vehicle is built for sale in Canada the parking brake switch is used for the Daytime Running Lamp (DRL) system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 4838 Brake Warning Indicator: Description and Operation Brake Warning Lamp Circuit Operation CIRCUIT OPERATION ABS Warning Lamp The ABS warning lamp is an output from the Controller Anti Lock Brake (CAB) and the ABS relay box. It is used to alert the operator of a problem in the ABS system. The G19 circuit from the CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster. Circuit G19 is also an output of the CAB to the ABS system relay contact side. Brake Warning Lamp The brake warning lamp is used to alert the operator of a problem in the vehicles braking system. This lamp also illuminates when the ignition switch is turned to the START position to perform a self check. Power for the lamp is supplied on circuit F11. This circuit is HOT when the ignition switch is in the OFF START, and RUN positions. The F11 circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. There are two switches used in this system and they are wired in parallel form. A parking brake switch, located on the parking brake mechanism, will illuminate the lamp if the normally OPEN switch is CLOSED. This switch is case grounded. The second switch used is the brake warning lamp switch. This switch in normally OPEN. When the brake system pressure is below the predetermined level the switch CLOSES and completes a path to ground. The G9 circuit is used to connect the switches to the cluster. Grounding for the brake warning lamp switch is completed on the Z1 circuit which terminates at the left strut tower. If the vehicle is built for sale in Canada the parking brake switch is used for the Daytime Running Lamp (DRL) system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 4839 Brake Warning Lamp Functional Check Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Guide Pin Bolts 16 ft.lb Banjo Bolt 24 ft.lb Bore Diameter 2.13 in Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Technician Safety Information Brake Caliper: Technician Safety Information WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Technician Safety Information > Page 4846 Brake Caliper: Vehicle Damage Warnings CAUTION: - Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. - Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. - Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. - When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. NOTE: - When being installed, extreme caution must be taken not to cross thread the caliper guide pin bolts. - Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. - When using Caliper Honing Tool, Special Tool C-4095, or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic 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, lint free cloth and then clean a second time. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Page 4847 Brake Caliper: Description and Operation Exploded View Of Caliper Fig. 2 Piston Seal Function GENERAL INFORMATION The caliper is mounted to the steering knuckle using bushings, sleeves and 2 guide pin bolts which thread directly into bosses on the steering knuckle. Two machined abutments on the steering knuckle position the caliper. The guide pin bolts, sleeves and bushings control the side to side movement of the caliper. The piston seal is designed to pull the piston back into the bore of the caliper when the brake pedal is released. This maintains the proper brake shoe to rotor clearance. The caliper is a one piece casting with the inboard side containing a single piston cylinder bore. The front disc brake caliper piston, is manufactured from a phenolic compound. The outside diameter of the caliper piston is 54 mm. A square cut rubber piston seal is located in a machined groove in the caliper cylinder bore. This provides a hydraulic seal between the piston and the cylinder wall. A rubber dust boot is installed in the cylinder bore opening and in a groove in the piston. This prevents contamination in the bore area. As front disc brake linings wear, master cylinder reservoir brake fluid level will drop. Fluid level should be checked after replacing linings. Front disc brakes are equipped with an audible wear sensor on the outboard brake pad. This sensor emits a sound when the brake lining may need inspection and/or replacement. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Page 4848 Brake Caliper: Testing and Inspection PISTON SEAL Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if scored. GUIDE PIN BUSHINGS Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Guide Pin Bushing Disassembly or Assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Removing Caliper Guide Pin Bolts Removing/Installing Brake Caliper Storing Caliper GENERAL INFORMATION During service procedures, grease or any other foreign material must be kept off caliper assembly, surfaces of braking rotor and external surfaces of hub. Handling of the braking rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. REMOVE 1. Raise vehicle on jackstands or centered on a hoist. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4851 2. Remove front wheel and tire assemblies from vehicle. 3. Remove the 2 caliper to steering knuckle guide pin bolts. 4. Remove brake caliper from steering knuckle, by first rotating bottom end of caliper away from steering knuckle. Then slide top of caliper down from the machined abutment on steering knuckle. 5. Support caliper from upper control arm to prevent weight of caliper from being supported by brake flex hose. Supporting disc brake caliper from flex hose can damage the hose. INSTALL 1. Lubricate both steering knuckle abutments with a liberal amount of Mopar R Multipurpose Lubricant, or equivalent. 2. If removed, install the front rotor on the hub, making sure it is squarely seated on face of hub. CAUTION:Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 3. Carefully position caliper and brake shoe assemblies over brake rotor by first hooking top of brake shoes on the machined abutment on upper steering knuckle. Then rotate the bottom of the brake caliper into position on the steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. NOTE: When being installed, extreme caution must be taken not to cross thread the caliper guide pin bolts. 4. Install the brake caliper guide pin bolts. Then tighten the guide pin bolts to a torque of 22 Nm (16 ft. lbs.). 5. Install the wheel and tire assembly 6. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 115 - 155 Nm (85 - 115 ft. lbs.). 7. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 8. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4852 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly PROCEDURE WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. 1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic fluid cannot get on rotor. Place a small piece of wood between the piston and caliper fingers. 2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold down the brake pedal to any position beyond the first inch of pedal travel. This will prevent loss of brake fluid from the master cylinder. 3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at frame rail. Plug brake tube and remove piston from opposite caliper using the same process as above for the first piston removal. 4. Disconnect the brake fluid flex hose from the caliper assembly. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin sleeves and guide pin bushings. Refer to Guide Pin Removal. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper and discard. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4853 Removing Piston Seal From Caliper 8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston bore. Discard old seal. Do not use a screw driver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove. 9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint residue can remain in caliper bore. Clean out all drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must be installed at assembly. Honing Brake Caliper Piston Bore 10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than 0.0254 mm 0.001 inch.. 11. 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. NOTE: When using Caliper Honing Tool, Special Tool C-4095, or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. NOTE: 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, lint free cloth and then clean a second time. CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. 12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is evidence of scratches, pitting or physical damage. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4854 Assembly PROCEDURE CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 1. Clamp caliper in a vise with protective caps installed on jaws of vise.. Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. 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 boot. 4. Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. Installing Piston Into Caliper Bore 5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6. Position dust boot into the counterbore of the caliper assembly piston bore. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4855 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171, or equivalent, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. Refer to Guide Pin Installation. 9. Install brake pads. Refer to Disc Brake Pad Installation. 10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described in Checking Brake Rotor for Runout and Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs). New seal washers MUST always be used when installing brake hose to caliper. 12. Bleed the brake system. Removal GENERAL INFORMATION The double pin caliper uses a sealed for life bushing and sleeve assembly If required this assembly can be serviced using the following procedure. PROCEDURE 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4856 Removing Inner Sleeve From Bushing 2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown above. Removing Bushing From Caliper 3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing. Installation PROCEDURE Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4857 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. Flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4858 Fig 7 Installing Caliper Sleeves 5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing through boot until one end of bushing is fully seated into seal groove on one end of sleeve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4859 Fig 8 Installed Caliper Bushing Sleeve 7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on sleeve. Be sure other end of bushing did not come out of seal grove in sleeve. 8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 4860 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 9.0 mm (3/8 inch) or less, they should be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Technician Safety Information Brake Pad: Technician Safety Information WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Technician Safety Information > Page 4866 Brake Pad: Vehicle Damage Warnings CAUTION: When prying the piston back into the bore of the caliper do not use a hard pry bar. The use of a hard pry bar will damage the braking surface of the rotor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. GENERAL INFORMATION If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it should be replaced immediately. During removal and installation of a wheel and tire assembly, use care not to strike the caliper. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. PROCEDURE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies from vehicle. CAUTION: When prying the piston back into the bore of the caliper do not use a hard pry bar. The use of a hard pry bar will damage the braking surface of the rotor. 3. Slightly pry the piston back into the bore of the disc brake caliper. The piston is to be pried back by inserting a soft tool (such as a trim stick) between the inboard brake shoe and the rotor and prying against the inboard brake shoe. This will force the piston back into the caliper. 4. Remove the 2 brake caliper to steering knuckle guide pin bolts. 5. Remove brake caliper from steering knuckle, by first rotating bottom of brake caliper away from the steering knuckle. Then slide top of brake shoes down and out from the top machined abutment on steering knuckle. 6. Support brake caliper from upper control arm to prevent weight of caliper from being supported by brake flex hose. Supporting disc brake caliper from flex hose can damage the hose. 7. Remove the brake rotor from the front hub. Removing/Installing Outboard Brake Pad 8. Remove outboard brake shoe by pushing the brake shoe inward until retaining pins on brake shoe can be removed from holes in caliper. Then slide the brake shoe off the caliper. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4869 Removing Inboard Brake Pad From Piston 9. Pull inboard brake shoe away from piston until retaining clip is free from cavity in piston. CALIPER INSPECTION Check caliper for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper and install a new seal and boot, (and piston if scored). Refer to Disc Brake Caliper Service and Repair. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Disc Brake Caliper Service and Repair. Installation WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. CALIPER INSPECTION Check caliper for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper and install a new seal and boot, (and piston if scored). Refer to Disc Brake Caliper Service and Repair. Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Disc Brake Caliper Service and Repair. PROCEDURE 1. Completely retract caliper piston back into piston bore of caliper assembly. This is required for caliper installation with new brake shoe assemblies. 2. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. Install the front rotor on the hub, making sure it is squarely seated on face of hub. 4. Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies (if equipped). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4870 Front Brake Pad Assembly Identification NOTE: The inboard and outboard brake shoes are not common. Be sure the correct outer brake shoe is installed in the correct caliper. The left and right outer brake shoes are different and must be installed correctly. The wear sensor and the hold down clip must be on the upper end of the caliper when the caliper and brake shoes are installed on the steering knuckle. Inboard Brake Shoe 5. Install the new inboard brake shoe assembly into the caliper piston by firmly pressing into piston bore. Be sure inboard brake shoe assembly is positioned squarely against face of caliper piston. Removing/Installing Outboard Brake Pad 6. Slide the new outboard brake shoe assembly onto the caliper assembly. CAUTION: Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. Also, make sure that caliper guide pin bushings and sleeves are clear of the steering knuckle bosses 7. Carefully position brake caliper and brake shoes over brake rotor by first hooking top of brake shoes onto upper abutment on steering knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4871 Then rotate caliper into position at bottom of steering knuckle. NOTE: When installing guide pin bolts, extreme caution should be taken not to cross thread the caliper guide pin bolts. 8. Install the caliper guide pin bolts and tighten to a torque of 22 Nm (16 ft. lbs.). 9. Install the wheel and tire assembly. 10. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 11. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4872 Brake Pad: Service and Repair Cleaning and Inspection LINING WEAR If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers. Remove the front disc brake shoes. Refer to Disc Brake Pad Rear Removal. Material Thickness The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 9.0 mm (3/8 inch) they should be replaced. Replace both brake shoe assemblies (inboard and outboard). It is necessary that both front wheel sets be replaced whenever brake shoe assemblies on either side are replaced. If Replacement Is Not Required If the brake shoe assemblies do not require replacement, reinstall, the assemblies making sure each brake shoe is returned to the original position. Refer to Disc Brake Pad Front Installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Brake Rotor Specifications Brake Rotor Specifications BRAKE ROTOR TYPE Ventilated ROTOR THICKNESS 22.87 - 23.13 mm (0.900 - 0.911 in.) MINIMUM ROTOR THICKNESS 21.4 mm (0.843 in.) Minimum allowable thickness markings are cast/stamped on an un-machined surface of the rotor. This marking includes 0.76 mm (0.030 in.) allowable rotor wear beyond the recommended 0.76 mm (0.030 in.) of rotor refacing. ROTOR THICKNESS VARIATION 0.013 mm (0.0005 in.) ROTOR RUNOUT * 0.13 mm (0.005 in.) * TIR - Total Indicator Reading (measured on vehicle) ROTOR MICRO-FINISH 15 - 80 RMS Minimum Brake Rotor Thickness Markings Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4876 Brake Rotor/Disc: Service Precautions NOTE: - Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action. - All rotors have markings for minimum allowable thickness cast on an un-machined surface of the rotor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4877 Brake Rotor/Disc: Testing and Inspection Checking Rotor For Runout Indexing Rotor And Hub Checking Hub For Runout GENERAL INFORMATION Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Before refinishing or refacing a rotor, the disc should be checked and inspected for the following conditions: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4878 ^ Braking surface scoring, rust, impregnation of lining material and worn ridges. ^ Excessive lateral runout or wobble. ^ Thickness variation (Parallelism). ^ Dishing or distortion (Flatness). If a vehicle has not been driven for a period of time, the rotor surface will rust in the area not covered by the brake lining and cause noise and chatter when the brakes are applied. Excessive wear and scoring of the rotor can cause temporary improper lining contact if ridges are not removed before installation of new brake pad assemblies. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock back. This will increase guide pin sleeve wear due to tendency of caliper to follow rotor wobble. Thickness variation in a rotor can also result in pedal pulsation, chatter and surge due to variation in brake output. This can also be caused by excessive runout in rotor or hub. Dishing or distortion can be caused by extreme heat and abuse of the brakes. RUNOUT On vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor runouts are separable). To measure runout on the vehicle, remove the wheel and reinstall the lug nuts tightening the rotor to the hub. Mount Dial Indicator, Special Tool C-3339 with Mounting Adapter, Special Tool SP-1910, or equivalents on steering arm. Dial indicator plunger should contact braking surface of rotor approximately one inch from edge of rotor. Check lateral runout (both sides of rotor) runout should not exceed 0.13 mm (0.005 inch). If runout is in excess of the specification, check the lateral runout of the hub face. Before removing rotor from hub, make a chalk mark across both the rotor and one wheel stud on the high side of runout so you'll know exactly how the rotor and hub was originally mounted. Remove rotor from hub. Install Dial Indicator, Special Tool C-3339 and Mounting Adapter, Special Tool SP- 1910, or equivalents on steering knuckle. Position stem so it contacts hub face near outer diameter. Care must be taken to position stem outside the stud circle but inside the chamfer on the hub rim. Clean hub surface before checking. Runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, hub must be replaced. Refer to Steering and Suspension. If hub runout does not exceed this specification, install rotor on hub with chalk marks two wheel studs apart. Tighten nuts in the proper sequence and torque to specifications. Finally, check runout of rotor to see if runout is now within specifications. If runout is not within specifications, install a new rotor or reface rotor, being careful to remove as little as possible from each side of rotor. Remove equal amounts from each side of rotor. Do not reduce thickness below minimum thickness cast into the unmachined surface of the rotor. Checking Rotor For Thickness Variation THICKNESS VARIATION Thickness variation measurements of rotor should be made in conjunction with runout. Measure thickness of rotor at 12 equal points with a micrometer at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary by more than 0.013 mm (0.0005 inch) rotor should be removed and resurfaced, or a new rotor installed. If cracks or burned spots are evident, rotor must be replaced. Light scoring and/or wear is acceptable. If heavy scoring or warping is evident, the rotor must be machined or replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4879 Brake Rotor/Disc: Service and Repair Fig 6 Refacing Brake Disc Fig 7 Refacing Brake Disc -- Final Finish Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4880 Minimum Brake Rotor Thickness Markings NOTE: - Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action. - All rotors have markings for minimum allowable thickness cast on an un-machined surface of the rotor. REFINISHING INFORMATION If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or pulsation, the rotor should be resurfaced or refaced. The previous image shows the location of measurements and specifications when servicing the rotor. This marking includes 0.76 mm (0.030 inch) allowable rotor wear beyond the recommended 0.76 mm (0.030 inch) of rotor refacing. The collets, shafts and adapters used the brake lathe and the bearing cups in the rotor MUST be clean and free from any chips or contamination. When mounting the rotor on the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. If the rotor is not mounted properly, the lateral runout will be worse after refacing or resurfacing than before. REFACING Refacing of the rotor is not required each time the brake pads are replaced. When refacing a rotor the required 0.10 mm (0.004 inch) Total Indicator Reading (TIR) and 0.013 mm (0.0005 inch) thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. The use of a double straddle cutter that machines both sides of the rotor at the same time is highly recommended. RESURFACING This operation can be used when rotor surface is rusty, has lining deposits or excessive lateral runout or thickness variation is evident. A sanding rotor attachment will remove surface contamination without removing much rotor material. It will generally follow variations in thickness that are in the rotor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Support Plate-to-spindle Attaching Bolts ................................................................................................................................................. 63 Nm (46 ft. lbs.) Tube Nut ............................................................................................................................ .................................................................... 17 Nm (145 in. lbs.) Hub And Bearing Assembly Retaining Nut .......................................................................................................................................... 250 Nm (185 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4885 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal Backing Plate: Service and Repair Removal PROCEDURE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly from vehicle. 3. Remove the dust cap from the rear hub and bearing assembly. 4. Remove the rear hub and bearing assembly retaining nut. Then remove the hub and bearing assembly from the rear spindle. 5. Remove rear brake shoe assemblies from the brake support plate. Refer to Rear Brake Shoes Service and Repair Removal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 4888 6. Disconnect rear brake flex hose tube from wheel cylinder and remove the brake flex hose bracket from the brake support plate. 7. Position a 1/2 wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable housing out of support plate. Remove wrench when retainer is free from the park brake cable mounting hole in the rear brake support plate. Alternate method is to use a aircraft type hose clamp over cable housing end fitting compressing the three fingers. 8. Remove the 4 brake support plate to knuckle attaching bolts and washer assemblies. Separate brake support plate from rear suspension knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Removal > Page 4889 Backing Plate: Service and Repair Installation PROCEDURE 1. Install gasket and brake support plate on rear spindle. Tighten the support plate-to-spindle attaching bolts to a torque of 63 Nm (46 ft. lbs.). 2. Insert parking brake cable end fitting into brake support plate. 3. Hand start hydraulic brake hose tube fitting to wheel cylinder. Tighten tube nut to a torque of 17 Nm (145 in. lbs.). 4. Install rear brake shoe assemblies on the brake support plate. Refer to Rear Brake Shoes Service and Repair Installation. 5. Install the rear hub and bearing on the rear spindle. Install a NEW hub and bearing assembly retaining nut. 6. Tighten the hub and bearing assembly retaining nut to a torque of 250 Nm (185 ft. lbs.). Install dust cap. 7. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 8. Install brake drum on rear hub/bearing assembly. 9. Bleed the vehicle's base brakes hydraulic system. 10. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 11. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection Brake Adjuster: Testing and Inspection Accessing The Automatic Adjuster Quadrant AUTOMATIC ADJUSTER QUADRANT TESTING 1. Place the vehicle on a frame contact hoist with a helper in the driver's seat to apply the brakes. 2. Raise the vehicle. 3. Remove the adjuster access plug from the rear brake support plate automatic adjuster access hole. NOTE: ^ This will allow access to the adjuster quadrant on the automatic adjuster mechanism. ^ To eliminate the possibility of maximum adjustment, insert a small screwdriver through the access hole in the support plate and back off adjuster quadrant approximately 4 to 5 notches. 4. Fully apply the brake pedal which will cause the brake shoes to leave the anchor. NOTE: ^ Upon application of the brake pedal, the adjuster quadrant should move. ^ A definite rotation of the adjuster quadrant should be observed if the automatic adjuster is working properly. ^ If one or more adjusters do not function properly, the respective drum must be removed for adjuster mechanism servicing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Drum Specifications Nominal Diameter ................................................................................................................................ ............................................................. 7.875" Maximum Machine Limit ...................................................................................................................... ............................................................ 7.904" Discard Diameter ................................................................................................................................. .............................................................. 7.921" Runout Limit ........................................................................................................................................ ............................................................. 0.006" Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4896 Brake Drum: Service and Repair Brake Drum And Hub And Bearing Assembly REMOVE If the vehicle has high mileage, the brake drums may have a ridge worn in them by the brake shoes. This ridge causes the brake drum to interfere with the brake shoes thus, not allowing the brake drum to be removed. Further clearance can be obtained by backing off the brake's automatic self adjuster mechanism, using the following procedure. 1. Remove the rubber plug from the brake support plate. 2. Insert a screwdriver, through the automatic adjuster access hole, in the rear brake support plate. Engage screwdriver with the teeth on the Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4897 adjuster mechanism quadrant. Then rotate quadrant so that the teeth on the quadrant are moved toward the front of the vehicle. This will back off the adjustment of the rear brake shoes. 3. Remove rear brake drum from the rear hub and bearing assembly. Measure drum runout and diameter. If not to specification, reface drum. (Runout should not exceed 0.1524 mm or 0.006 inch). The diameter variation (oval shape) of the drum braking surface must not exceed either 0.0635 mm (0.0025 inch) in 30° or 0.0889 mm (0.0035 inch) in 360°. All brake drums are marked with the maximum allowable brake drum diameter. INSTALL 1. Install rear brake drum on rear hub and bearing assembly. 2. Install the wheel and tire assembly. 3. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 4. Adjust rear brakes. The rear brakes on this vehicle are adjusted by depressing the brake pedal as far as possible 2 or 3 times. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Brake Shoe Lining Thickness Measurement Measure the combined thickness of the leading and trailing brake shoe and lining. NOTE: The lining used on the leading and trailing brake shoes of this vehicle are of different thicknesses. Therefore, the minimum thickness measurement for the replacement of the leading and trailing are different. Minimum Combined Brake Shoe / Lining Thickness Leading shoe (front) ............................................................................................................................ ................................................. 3.0 mm (0.118 in.) Trailing shoe (rear) .............................................. ..................................................................................................................... 2.8 mm (0.110 in.) or less Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 WARNING: ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS, SOME AFTER MARKET BRAKE LININGS MAY CONTAIN ASBESTOS. THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE. ALWAYS WEAR A RESPIRATOR WHEN CLEANING BRAKE COMPONENTS AS ASBESTOS CAN CAUSE SERIOUS BODILY HARM SUCH AS ASBESTOSIS AND OR CANCER. NEVER CLEAN BRAKE COMPONENTS BY USING COMPRESSED AIR, USE ONLY A VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF BRAKE DUST. IF A VACUUM CLEANER IS NOT AVAILABLE, CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS. DO NOT CREATE BRAKE LINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIR TIGHT BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA), FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. GENERAL INFORMATION During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing assembly. The original equipment rear drum brake assemblies used on this vehicle are supplied by Varga Nm.A. Inc. Drum Brake Assembly PROCEDURE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove the rear wheel and tire assemblies from the vehicle. NOTE: If the vehicle has high mileage, the brake drums may have a ridge worn in them by the brake shoes. This ridge causes the brake drum to interfere with the brake shoes, not allowing the brake drum to be removed. Further clearance can be obtained by fully backing oft the brakes automatic self adjuster mechanism, using the following procedure. 3. Remove the rubber plug from the top of brake support plate. 4. Insert a screwdriver, through the automatic adjuster access hole, in the rear brake support plate. Engage screwdriver with the teeth on the adjuster mechanism quadrant; Then rotate quadrant so that teeth on quadrant, are moved toward the front of the vehicle. Continue moving quadrant toward front of vehicle until it stops moving. This will fully back off the adjustment of the rear brake shoes allowing brake drum to be removed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4903 5. Remove rear brake drum to hub/bearing retaining nuts (if equipped). Then remove rear brake drum from hub and bearing assembly. 6. Remove the actuating spring from the automatic adjuster mechanism and the trailing brake shoe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4904 7. Remove the upper return spring from the leading and trailing brake shoe assembly. 8. Remove the lower return spring from the leading and trailing brake shoe assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4905 9. Remove the brake shoe retainer and pin from the leading brake shoe assembly. 10. Remove the leading brake shoe and the adjuster mechanism as an assembly, from the rear brake support plate. The adjuster mechanism can not be separated from the leading brake shoe until the brake shoe and adjuster mechanism is removed from the support plate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4906 11. Remove the brake shoe retainer and pin, from the trailing brake shoe. 12. Remove the trailing brake shoe assembly from the brake support plate. CAUTION: On this vehicle, the park brake actuating lever is permanently attached to the trailing brake shoe assembly. Do not attempt to remove it from the original brake shoe assembly or reuse the original actuating lever on a replacement brake shoe assembly. All replacement brake shoe assemblies for this vehicle must have the actuating lever as part of the trailing brake shoe assembly. 13. Remove the park brake cable from the park brake actuating lever, attached to the trailing brake shoe assembly. Do not attempt to remove actuating lever from brake shoe assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4907 14. Remove the automatic adjuster mechanism from the original leading brake shoe assembly for installation on the replacement brake shoe, using the following procedure. Fully extend the adjuster mechanism in the direction shown. Then, with adjuster mechanism fully extended, rotate the adjuster mechanism in the direction shown to separate adjuster mechanism from leading brake shoe. CLEANING AND INSPECTION Clean metal portion of brake shoes. Check to see if shoes are bent. Lining should show contact across entire width and from heel to toe, otherwise replace. Shoes with lack of contact at toe or heel may be improperly ground. Clean and inspect the brake support plate and the automatic self adjusting mechanism. Visually examine the adjuster assembly to ensure it is functioning correctly by checking for the following operation. ^ Be sure the quadrant is free to rotate throughout its entire tooth contact range. ^ Ensure that the quadrant is free to slide the full length of its mounting slot in the adjuster mechanism. ^ Inspect the quadrant spring for any signs of excessive wear or damage. ^ Ensure that the knurled pin is securely attached to the adjuster mechanism and that its teeth are not damaged. ^ Overall, examine the adjuster mechanism for excessive wear or damage and replace if necessary. If the adjuster mechanism is re-useable, apply a light coat of Mopar Multi-Purpose Lubricant or equivalent, between the quadrant and the strut of the adjuster mechanism.If old springs have overheated or are damaged, replace. Overheating indications are paint discoloration or distorted end coils. Installation CLEANING AND INSPECTION Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4908 Clean metal portion of brake shoes. Check to see if shoes are bent. Lining should show contact across entire width and from heel to toe, otherwise replace. Shoes with lack of contact at toe or heel may be improperly ground. Clean and inspect the brake support plate and the automatic self adjusting mechanism. Visually examine the adjuster assembly to ensure it is functioning correctly by checking for the following operation. ^ Be sure the quadrant is free to rotate throughout its entire tooth contact range. ^ Ensure that the quadrant is free to slide the full length of its mounting slot in the adjuster mechanism. ^ Inspect the quadrant spring for any signs of excessive wear or damage. ^ Ensure that the knurled pin is securely attached to the adjuster mechanism and that its teeth are not damaged. ^ Overall, examine the adjuster mechanism for excessive wear or damage and replace if necessary. If the adjuster mechanism is re-useable, apply a light coat of Mopar Multi-Purpose Lubricant or equivalent, between the quadrant and the strut of the adjuster mechanism.If old springs have overheated or are damaged, replace. Overheating indications are paint discoloration or distorted end coils. PROCEDURE Leading Brake Shoes NOTE: The leading rear brake shoes on this vehicle are designated for which side of the vehicle they are to be installed on. When correctly installed, the web reinforcement plate on the brake shoes will be facing toward the brake support plate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4909 1. Lubricate the eight brake shoe contact areas (indicated by arrows) on the support plate and anchor using Mopar Multi-Purpose Lubricant or equivalent. 2. Install the park brake cable on the park brake actuating lever of the trailing brake shoe. CAUTION:The leading and trailing brake shoes used on the rear brakes of this vehicle are unique (handed) for the left and right side of the vehicle. Care must be taken to ensure the brake shoes are properly installed on the vehicle. When the trailing brake shoes are properly installed on the correct side of the vehicle, the park brake actuating lever will be positioned behind the brake shoe web. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4910 3. Install the correctly handed trailing brake shoe on the support plate so it is squarely seated on the shoe contact areas. Then install the brake retainer on the retainer pin. 4. Install the automatic self adjuster mechanism on the correct leading brake shoe assembly using the reverse procedure as indicated in Step 14 of the brake shoe removal procedure. Refer to for the correct installation of the adjuster mechanism on the leading brake shoe. NOTE: When installing the leading brake shoe, the web support plate must be facing the brake support plate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4911 5. Install the leading brake shoe and the adjuster mechanism as an assembly on the brake support plate. 6. Be sure leading brake shoe assembly is squarely seated on the brake support plate shoe contact areas. Then install the brake retainer on the retainer pin. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4912 7. Install the lower return spring onto the leading and trailing brake shoe assembly. CAUTION: The upper brake shoe return spring and adjuster mechanism actuating spring are unique for the side of the vehicle they are used on. The springs are colored for identification of which side of the vehicle they are to be used on. The left side springs are colored green and the right side springs are blue. 8. Install the upper return spring (blue right side, green left side) on the leading brake shoe first, then on the trailing brake shoe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4913 9. Install the automatic adjuster actuation spring first on the trailing brake shoe and then hook it onto the adjuster mechanism. 10. Install the rear brake drums on the hubs. 11. Install the wheel and tire assemblies. 12. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm.m (80 - 110 ft. lbs.). 13. Lower vehicle. 14. Adjust rear brake shoes. Brake shoes will adjust by fully depressing the brake pedal 2 to 3 times. Brake shoes should now be correctly adjusted and will not require any type of manual adjustment. 15. Road test vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4914 Brake Shoe: Service and Repair Cleaning and Inspection Clean metal portion of brake shoe. Check to see if shoes are bent. Lining should show contact across entire width and from heel to toe, otherwise replace. Measure the combined thickness of the leading and trailing brake shoe and lining. The lining used on the leading and trailing brake shoes of this vehicle are of different thicknesses. Therefore, the minimum thickness measurement for the replacement of the leading and trailing brake shoes are different. When measuring the thickness, the measurement is the combined thickness of the brake shoe rim and the brake shoe lining. The minimum combined leading brake shoe rim and lining thickness specification for replacement is 3.0 mm. The minimum combined trailing brake shoe rim and lining thickness specification for replacement is 2.8 mm or less. Shoes with lack of contact at toe or heel may be improperly ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder 97 in.lb Tube Nut 145 in.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4918 Rear Wheel Cylinder (Exploded View) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVE With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. 1. In case of a leak, remove brake shoes (replace if soaked with grease or brake fluid.) 2. Disconnect rear brake flex hose tube from wheel cylinder and remove the flex hose routing bracket from the brake support plate. 3. Remove rear wheel cylinder attaching bolts. Then pull wheel cylinder assembly off brake support plate. INSTALL 1. Apply a small bead of silicone sealer around the mating surface of the wheel cylinder to brake support plate. 2. Install wheel cylinder onto brake support plate. Tighten the attaching bolts to a torque of 11 Nm (97 in. lbs.). 3. Hand start hydraulic brake hose tube fitting to wheel cylinder. Tighten the tube nut to a torque of 17 Nm (145 in. lbs.). 4. Install brake shoes on support plate. Refer to Service and Repair Installation. 5. Install rear brake drum onto rear hub. 6. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 7. Bleed the entire brake system. 8. Adjust the rear brakes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4921 Wheel Cylinder: Service and Repair Cleaning and Inspection With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4922 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Fig 3 Wheel Cylinder DISASSEMBLE To disassemble the wheel cylinders, proceed as follows: 1. Pry boots away from cylinders and remove. 2. Press IN on one piston to force out opposite piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston that remain in the wheel cylinder. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; DO NOT USE ANY PETROLEUM BASE SOLVENTS. clean thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and pitting. Do not use a rag as lint from the rag will stick to bore surfaces.. 4. 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. ASSEMBLE 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 pistons or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the wheel cylinder cups with Mopar Protect-A-Cup Lubricant. 3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Coat the interior surfaces of the push on boots with the Mopar Protect-A-Cup Lubricant 6. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures GENERAL INFORMATION The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The Antilock Brake System (ABS), particularly the Hydraulic Control Unit (HCU), should only be bled when the HCU is. replaced or removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During Bleeding Operations - be sure that the brake fluid level remains close to the FULL level in the reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The Bendix ABX-4 Brake System must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. Refer to Brakes Service and Repair for the proper bleeding procedure to be used. This brake system can be either pressure bled or manually bled. The ABS portion of brake system MUST be bled separately. This bleeding procedure requires the use of the DRB scan tool and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a Manual bleeding procedure or standard Pressure Bleeding Equipment. If the brake system is to be bled using pressure bleeding equipment, refer to Brakes Service and Repair. 1. Assemble and install all brake system components on vehicle making sure all hydraulic fluid lines are installed and properly torqued. System Diagnostic Connector Location 2. Connect the DRB scan tool to the diagnostics connector. The diagnostics connector is located under the lower instrument panel next to the left kick panel. 3. Using the DRB scan tool, check to make sure the CAB does not have any fault codes stored. If it does, remove them using the DRB scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure as outlined in Brakes Service and Repair. 5. Using the DRB scan tool, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and free of bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brake are operating correctly and that pedal is solid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4928 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Air Trapped In Brake System Method For Purging Air From Brake System Bleeder Screw CAUTION: - Before removing the Master Cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. - Use bleeder tank Special Tool C-3496-B, or equivalent with required adapter for the master cylinder reservoir to pressurize the hydraulic system for bleeding. NOTE: - For bleeding the ABS hydraulic system, refer to Hydraulic Control Unit. - Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. PROCEDURE When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4929 Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The following wheel sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel 1. Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Open the bleeder screw at least one full turn or more to obtain an steady stream of brake fluid. 3. After 4 to 8 ounces of fluid has been bled through the brake and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 4. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder. It must stay at the proper level so air will not be allowed to reenter the brake system through the master cylinder reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Guide Pin Bolts 16 ft.lb Banjo Bolt 24 ft.lb Bore Diameter 2.13 in Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Technician Safety Information Brake Caliper: Technician Safety Information WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Technician Safety Information > Page 4935 Brake Caliper: Vehicle Damage Warnings CAUTION: - Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. - Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. - Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. - When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. NOTE: - When being installed, extreme caution must be taken not to cross thread the caliper guide pin bolts. - Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. - When using Caliper Honing Tool, Special Tool C-4095, or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic 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, lint free cloth and then clean a second time. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Page 4936 Brake Caliper: Description and Operation Exploded View Of Caliper Fig. 2 Piston Seal Function GENERAL INFORMATION The caliper is mounted to the steering knuckle using bushings, sleeves and 2 guide pin bolts which thread directly into bosses on the steering knuckle. Two machined abutments on the steering knuckle position the caliper. The guide pin bolts, sleeves and bushings control the side to side movement of the caliper. The piston seal is designed to pull the piston back into the bore of the caliper when the brake pedal is released. This maintains the proper brake shoe to rotor clearance. The caliper is a one piece casting with the inboard side containing a single piston cylinder bore. The front disc brake caliper piston, is manufactured from a phenolic compound. The outside diameter of the caliper piston is 54 mm. A square cut rubber piston seal is located in a machined groove in the caliper cylinder bore. This provides a hydraulic seal between the piston and the cylinder wall. A rubber dust boot is installed in the cylinder bore opening and in a groove in the piston. This prevents contamination in the bore area. As front disc brake linings wear, master cylinder reservoir brake fluid level will drop. Fluid level should be checked after replacing linings. Front disc brakes are equipped with an audible wear sensor on the outboard brake pad. This sensor emits a sound when the brake lining may need inspection and/or replacement. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Page 4937 Brake Caliper: Testing and Inspection PISTON SEAL Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if scored. GUIDE PIN BUSHINGS Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Refer to Guide Pin Bushing Disassembly or Assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Removing Caliper Guide Pin Bolts Removing/Installing Brake Caliper Storing Caliper GENERAL INFORMATION During service procedures, grease or any other foreign material must be kept off caliper assembly, surfaces of braking rotor and external surfaces of hub. Handling of the braking rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings. NOTE: Before vehicle is moved after any brake service work, pump the brake pedal several times to insure the vehicle has a firm brake pedal. REMOVE 1. Raise vehicle on jackstands or centered on a hoist. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4940 2. Remove front wheel and tire assemblies from vehicle. 3. Remove the 2 caliper to steering knuckle guide pin bolts. 4. Remove brake caliper from steering knuckle, by first rotating bottom end of caliper away from steering knuckle. Then slide top of caliper down from the machined abutment on steering knuckle. 5. Support caliper from upper control arm to prevent weight of caliper from being supported by brake flex hose. Supporting disc brake caliper from flex hose can damage the hose. INSTALL 1. Lubricate both steering knuckle abutments with a liberal amount of Mopar R Multipurpose Lubricant, or equivalent. 2. If removed, install the front rotor on the hub, making sure it is squarely seated on face of hub. CAUTION:Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 3. Carefully position caliper and brake shoe assemblies over brake rotor by first hooking top of brake shoes on the machined abutment on upper steering knuckle. Then rotate the bottom of the brake caliper into position on the steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. NOTE: When being installed, extreme caution must be taken not to cross thread the caliper guide pin bolts. 4. Install the brake caliper guide pin bolts. Then tighten the guide pin bolts to a torque of 22 Nm (16 ft. lbs.). 5. Install the wheel and tire assembly 6. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 115 - 155 Nm (85 - 115 ft. lbs.). 7. Remove jackstands or lower hoist. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. 8. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4941 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly PROCEDURE WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. 1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic fluid cannot get on rotor. Place a small piece of wood between the piston and caliper fingers. 2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold down the brake pedal to any position beyond the first inch of pedal travel. This will prevent loss of brake fluid from the master cylinder. 3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at frame rail. Plug brake tube and remove piston from opposite caliper using the same process as above for the first piston removal. 4. Disconnect the brake fluid flex hose from the caliper assembly. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin sleeves and guide pin bushings. Refer to Guide Pin Removal. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper and discard. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4942 Removing Piston Seal From Caliper 8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston bore. Discard old seal. Do not use a screw driver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove. 9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint residue can remain in caliper bore. Clean out all drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must be installed at assembly. Honing Brake Caliper Piston Bore 10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than 0.0254 mm 0.001 inch.. 11. 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. NOTE: When using Caliper Honing Tool, Special Tool C-4095, or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. NOTE: 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, lint free cloth and then clean a second time. CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. 12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is evidence of scratches, pitting or physical damage. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4943 Assembly PROCEDURE CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 1. Clamp caliper in a vise with protective caps installed on jaws of vise.. Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. 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 boot. 4. Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. Installing Piston Into Caliper Bore 5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6. Position dust boot into the counterbore of the caliper assembly piston bore. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4944 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171, or equivalent, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. Refer to Guide Pin Installation. 9. Install brake pads. Refer to Disc Brake Pad Installation. 10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described in Checking Brake Rotor for Runout and Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs). New seal washers MUST always be used when installing brake hose to caliper. 12. Bleed the brake system. Removal GENERAL INFORMATION The double pin caliper uses a sealed for life bushing and sleeve assembly If required this assembly can be serviced using the following procedure. PROCEDURE 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4945 Removing Inner Sleeve From Bushing 2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown above. Removing Bushing From Caliper 3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing. Installation PROCEDURE Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4946 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. Flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4947 Fig 7 Installing Caliper Sleeves 5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing through boot until one end of bushing is fully seated into seal groove on one end of sleeve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4948 Fig 8 Installed Caliper Bushing Sleeve 7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on sleeve. Be sure other end of bushing did not come out of seal grove in sleeve. 8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 4949 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4953 Brake Fluid: Service Precautions CAUTION: Use only Mopar brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4954 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4955 Brake Fluid: Service and Repair Master Cylinder Fluid Level CAUTION:Use only Mopar brake fluid or an equivalent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications. Do not use petroleum-based fluid because seal damage in the brake system will result. Check master cylinder reservoir brake fluid level a minimum of twice a year. Master cylinder reservoirs are marked with the words FULL AND MIN indicating proper range of the master cylinder fluid level. If necessary, add specified brake fluid bringing level to the FULL mark on the side of the master cylinder brake fluid reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations Master Cylinder Fluid Level Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 4959 Brake Fluid Level Switch: Service and Repair GENERAL INFORMATION The master cylinder or brake fluid reservoir does not have to be removed from vehicle for replacement of the brake fluid level sensor. Master Cylinder Fluid Level Sensor 1. Remove wiring harness connector from brake fluid reservoir level sensor. Brake Fluid Level Switch Retaining Tabs 2. Compress retaining tabs on end of brake fluid level switch. Removing/Installing Fluid Reservoir Level Switch 3. While compressing retaining tabs, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Correctly align the replacement level switch with its mounting hole in the brake fluid reservoir. Push switch into fluid reservoir until retaining tabs are fully expanded on opposite side of fluid reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 4960 5. Install the wiring harness connector onto the brake fluid level switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation Brake Hose/Line: Description and Operation The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The chassis tubes are steel with a corrosion resistant coating applied to the external surfaces and the flex hoses are made of reinforced rubber. The rubber flex hoses allow for the movement of the vehicle's suspension. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Brake Hoses Brake Hose/Line: Testing and Inspection Brake Hoses Flexible rubber hose is used at both front and rear brakes. Inspection of brake hoses should be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first (every engine oil change). Inspect hydraulic brake hoses for severe surface cracking, scuffing, worn spots or physical damage. If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Brake Hoses > Page 4966 Brake Hose/Line: Testing and Inspection Brake Lines The steel brake tubing should be inspected periodically for evidence of corrosion, physical damage or contact with moving or hot components of the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Replacement Brake Hose/Line: Service and Repair Brake Line Replacement GENERAL INFORMATION Always use Mopar replacement brake hose assemblies to ensure 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. Hose assemblies for each brake are unique and not interchangeable.Use new copper seal washers on all connections using Banjo Bolts and tighten all fittings to their specified torques. PROCEDURE The flexible front 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 brake tubing, before attaching to front frame rail. Then tighten all brake line fittings to specified torque. On vehicles equipped with rear drum brakes, install rear brake hoses first to wheel cylinders and rear struts and then attach hose bracket to body. On vehicles equipped with rear disc brakes, attach brake hoses to calipers and struts first and then attach brake hose bracket to body. Following this procedure will reduce potential for twisting brake during installation procedure. Only double wall 4.75 mm (3/16 in.) steel brake line tubing, with Al- Rich/ZN-AL alloy coating should be used for replacement. Care must be taken when replacing brake tubing, to be sure the proper bending and flaring tools and procedures are used to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Replacement > Page 4969 Brake Hose/Line: Service and Repair Brake Tubing Repair/Tube Flaring Tube End Properly Prepared For Flaring Double Inverted Brake Tube Flare NOTE: Place tube nut on tubing before flaring the tubing. GENERAL INFORMATION Only double wall 4.75 mm (3/16 in.) steel tubing with Al-rich/ZN-AL alloy coating and the correct tube nuts are to be used for replacement of a hydraulic brake tube. Care should be taken when repairing brake tubing, to be sure the proper bending and flaring tools and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. Using Tubing Cutter, Special Tool C-3478-A or equivalent, cut off damaged seat or tubing. Ream out any burrs or rough edges showing on inside of tubing. This will make the ends of tubing square and ensure better seating of flared end tubing. DOUBLE INVERTED TUBING FLARES To make a double inverted tubing flare. Open handles of Flaring Tool, Special Tool C-4047 or equivalent. Then rotate jaws of tool until the mating jaws of tubing size are centered between vertical posts on tool. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Replacement > Page 4970 Place gauge (Form A) on edge over end of brake tubing. Push tubing through jaws until end of tubing contacts the recessed notch in gauge matching the tubing size. Squeeze handles of flaring tool and lock tubing in place. Place 3/16 inch plug of gauge (A) down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess of disc. Screw in until plug gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the tubing. Remove gauge and continue to screw down until tool is firmly seated in tubing. Remove tubing from flaring tool and inspect seat. Refer to tube routing diagrams for proper brake tube routing and clip locations. Replace any damaged tube routing clips. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Replacement > Page 4971 Brake Hose/Line: Service and Repair Brake Tubing/Hose Replacement GENERAL INFORMATION Always use Mopar replacement brake hose assemblies to ensure 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. Hose assemblies for each brake are unique and not interchangeable.Use new copper seal washers on all connections using Banjo Bolts and tighten all fittings to their specified torques. PROCEDURE The flexible front 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 brake tubing, before attaching to front frame rail. Then tighten all brake line fittings to specified torque. On vehicles equipped with rear drum brakes, install rear brake hoses first to wheel cylinders and rear struts and then attach hose bracket to body. On vehicles equipped with rear disc brakes, attach brake hoses to calipers and struts first and then attach brake hose bracket to body. Following this procedure will reduce potential for twisting brake during installation procedure. Only double wall 4.75 mm (3/16 in.) steel brake line tubing, with Al- Rich/ZN-AL alloy coating should be used for replacement. Care must be taken when replacing brake tubing, to be sure the proper bending and flaring tools and procedures are used to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Page 4972 Cutting And Flaring Of Brake Fluid Tubing Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes Brake Proportioning/Combination Valve: Specifications With Antilock Brakes Torque Proportioning Valve ................................................................................................................. .................................................... 40 Nm (30 ft. lbs.) TOrque Tube Nut .............................................. ..................................................................................................................................... 17 Nm (145 in. lbs.) Split Point ..................................................................................................................................... .............................................................................. 500 psi Slope ........................................................ .............................................................................................................................................................. ......... 0.43 Inlet Pressure .................................................................................................................... ........................................................................................ 1000 psi Outlet Pressure ............................ .............................................................................................................................................................. .......... 600-700 psi Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes > Page 4977 Brake Proportioning/Combination Valve: Specifications Without Antilock Brakes Brake Line Tube Nuts At The Proportioning Valve .............................................................................................................................. 17 Nm (145 in. lbs.) Split Point ..................................................................................................................................... .............................................................................. 500 psi Slope ........................................................ .............................................................................................................................................................. ......... 0.43 Inlet Pressure .................................................................................................................... ........................................................................................ 1000 psi Outlet Pressure ............................ .............................................................................................................................................................. .......... 600-700 psi Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4978 Brake Proportioning/Combination Valve: Service Precautions CAUTION: - Be sure the pressure test fitting being installed into the Hydraulic Control Unit (HCU) has the correct thread sizes for installation into the HCU and installation of the proportioning valve. - Be sure the pressure test fitting being installed into proportioning valve, has the correct thread sizes for installation into the proportioning valve and installation of brake tube fitting into proportioning valve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4979 Brake Proportioning/Combination Valve: Application and ID Fig 35 Type 3 Proportioning Valve Identification SALES CODE BRAKE SYSTEM TYPE IDENTIFICATION BRA 14" Disc/Drum Bar Code Label BRB 15" Disc/Drum Bar Code Label BRJ 14" Disc/Drum Bar Code Label BRK 15" Disc/Drum Bar Code Label Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4980 Brake Proportioning/Combination Valve: Description and Operation Fig 35 Type 3 Proportioning Valve Identification Proportioning Valves For Non-ABS Vehicles GENERAL INFORMATION This vehicle is available with two different master cylinder assemblies. This vehicle uses screw-in proportioning valves in-line with the rear brake tubes on vehicles not equipped with Antilock Brakes. On vehicles equipped with the Allied Signal ABX-4 Antilock Brake system, the proportioning valves are located at the rear brake outlet ports of the Hydraulic Control Unit (HCU). The Proportioning Valve can be identified by the bar code label and stamp on the Proportioning Valve. Be sure replacement Proportioning Valve has the same stamp as the Proportioning Valve being replaced. These new in-line proportioning valves used on this vehicle replace the combination valve used in prior designs. With this new design, the chassis brake tubes connect directly from the master cylinder or HCU to the brake flex hose. Vehicles not equipped with ABS use a master cylinder incorporating the standard type compensating port design. Vehicles which are equipped with ABS use a master cylinder having a center valve design. In addition, the ABS master cylinder is a 2 outlet port design and the non-ABS master cylinder is a four outlet design. The non-ABS brake system uses two screw-in proportioning valves attached directly in-line with the rear brake tubes. The non-ABS equipped proportioning valves are located in the same area of the vehicle as the hydraulic unit on ABS equipped vehicles. FUNCTION Proportioning valves balance front to rear braking by controlling at a given ratio, the increase in rear brake system hydraulic pressure above a preset level (split point). Under light pedal application, the proportioning valve allows full hydraulic pressure to. be applied to the rear brakes. IDENTIFICATION There are two proportioning valve assemblies used in each vehicle. Due to differences in thread sizes, each proportioning valve has a different part number. During any service procedures identify valve assemblies by supplier part number and or the bar code label and stamp identification band. All vehicle brake systems use a common calibration for the proportioning valve. The split point is 500 psi and the slope is 0.43. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing Brake Proportioning/Combination Valve: Testing and Inspection Proportioning Valve Testing With Antilock Brakes Proportioning Valve Locations On Hydraulic Control Unit PROCEDURES 1. After road testing vehicle to determine which rear wheel exhibits premature rear wheel skid, to determine which proportioning valve needs to be tested. 2. Remove hydraulic brake line from proportioning valve controlling the rear wheel of the vehicle which has premature wheel skid. 3. Then remove proportioning valve from that outlet port of the Hydraulic Control Unit HCU. CAUTION: Be sure the pressure test fitting being installed into the HCU, has the correct thread sizes for installation into the HCU and installation of the proportioning valve. 4. Install Pressure Test Fitting, Special Tool 6805-1 or 6805-2, or equivalents into the outlet port of the HCU. 5. Install proportioning valve into pressure test fitting installed in the HCU outlet port. CAUTION: Be sure the pressure test titling being installed into proportioning valve, has the correct thread sizes for installation into the proportioning valve and installation of brake tube titling into proportioning valve. 6. Install Pressure Test Fitting, Special Tool 6805-3 or 6805-4, or equivalents into the outlet of the proportioning valve. 7. Connect brake hydraulic line onto pressure test fitting installed in proportioning valve. 8. Install a Pressure Gauge, Special Tool C-4007-A, or equivalent into each pressure test fitting. Bleed air out of hose from pressure test fitting to pressure gauge, at pressure gauge to remove all trapped air. 9. With the aid of a helper, apply pressure to the brake pedal until reading on proportioning valve inlet gauge, is at the pressure shown on the following chart. Then check the pressure reading on the proportioning valve outlet gauge. If proportioning valve outlet pressure does not agree with value shown on the following chart, when inlet pressure shown on chart is obtained, replace the proportioning valve. If proportioning valve is within pressure specifications do not replace proportioning valve. 10. Check rear wheel brake shoe linings for contamination or for replacement brake shoes not meeting OEM brake lining material specifications. These conditions can also be a possible cause for a premature rear wheel skid. 11. Install proportioning valve in HCU and hand tighten until proportioning is fully installed and 0-ring seal is seated into HCU. Then torque proportioning valve to 40 Nm (30 ft. lbs.). 12. Install brake tube on proportioning valve. Torque tube nut to 17 Nm (145 in-lbs.). 13. Bleed the affected brake line. See Bleeding Brake System in the Service Adjustments section of the manual for proper bleeding procedure. Without Antilock Brakes Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing > Page 4983 Proportioning Valves For Non-ABS Vehicles TESTING 1. After road testing vehicle to determine which rear wheel exhibits premature rear wheel skid, to determine which proportioning valve needs to be tested. 2. Remove hydraulic brake line from proportioning valve controlling the rear wheel of the vehicle which has premature wheel skid. 3. Then remove the proportioning valve from the rear brake line. CAUTION: Be sure the pressure test fitting being installed into proportioning valve, has the correct thread sizes for installation into the proportioning valve and installation of brake tube fitting. 4. Install Pressure Test Fitting, Special Tool 6805-1 or 6805-2, or equivalents on rear brake tube which the proportioning valve was removed from. 5. Install proportioning valve into pressure test fitting installed on rear brake tube. CAUTION: Be sure the pressure test fitting being installed into proportioning valve, has the correct thread sizes for installation into the proportioning valve and installation of brake tube fitting. 6. Install Pressure Test Fitting, Special Tool 6805-3 or 6805-4, or equivalents into outlet of the proportioning valve. 7. Connect brake hydraulic line onto pressure test fitting installed in proportioning valve 8. Install a Pressure Gauge, Special Tool C-400 7-A, or equivalent into each pressure test fitting. Bleed air out of hose from pressure test fitting to pressure gauge, at pressure gauge to remove all trapped air. hose. 9. With the aid of a helper, apply pressure to the brake pedal until reading on proportioning valve inlet gauge, is at the pressure shown on the following chart. Then check the pressure reading on the proportioning valve outlet gauge. If proportioning valve outlet pressure does not agree with value shown on the following chart, when inlet pressure shown on chart is obtained, replace the proportioning valve. If proportioning valve is within pressure specifications do not replace proportioning valve. 10. Check rear wheel brake shoe linings for contamination or for replacement brake shoes not meeting OEM brake lining material specifications. These conditions can also be a possible cause for a premature rear wheel skid. 11. Install proportioning valve in rear brake line and hand tighten both tube nuts until they are fully seated in proportioning valve. 12. Tighten both brake line tube nuts at the proportioning valve to a torque of 17 Nm (145 in-lbs.). 13. Bleed the affected brake line. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing > Page 4984 Brake Proportioning/Combination Valve: Testing and Inspection With ABS Proportioning Valve Locations On Hydraulic Control Unit DIAGNOSIS If premature rear wheel skid occurs on hard brake application, it could be an indication that a malfunction has occurred with one of the proportioning valves. One proportioning valve controls the right rear brake, and the other proportioning valve controls the left rear brake. Therefore, a road test to determine which rear brake slides first is essential. Once the wheel which is skidding first is determined, use the following procedure to diagnose the proportioning valve. TESTING The test procedure for a premature rear wheel skid is the same for both rear wheel proportioning valves. The pressure test fittings used for each proportioning valve though are different due to proportioning valve and brake tube nut thread sizes being unique for each rear wheel. After road testing vehicle to determine which wheel skids first, the proper test fittings required will have to be determined. Then follow the procedure below for testing the required proportioning valve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Proportioning Valve Testing > Page 4985 Brake Proportioning/Combination Valve: Testing and Inspection Without ABS Proportioning Valves For Non-ABS Vehicles CAUSES If premature rear wheel skid occurs on a hard brake application, it could be an indication that a malfunction has occurred with one of the rear brake proportioning valves. TESTING One proportioning valve controls the right rear brake, and the other proportioning valve controls the left rear brake. Therefore, a road test to determine which rear brake slides first is essential. Once the wheel which slides first is determined, refer to procedures to diagnose the proportioning valve. The test procedure for a premature rear wheel skid is the same for both rear wheel proportioning valves. The pressure test fittings used for each proportioning valve though are different due to proportioning valve and brake tube nut thread sizes being unique for each rear wheel. After road testing vehicle to determine which wheel skids first, the proper test fittings required will have to be determined. Then refer to procedures for testing the required proportioning valve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes Brake Proportioning/Combination Valve: Service and Repair With Antilock Brakes Fig 35 Type 3 Proportioning Valve Identification Rear Wheel Proportioning Valve Location On HCU GENERAL INFORMATION The HCU does not require removal from the vehicle for the replacement of the proportioning valves. Use the proportioning valve test procedure under Testing and Inspection to determine which proportioning valve requires replacement, then replace it using procedure below. REMOVE 1. Disconnect the brake tube fitting from the proportioning valve requiring removal from the HCU. 2. Remove proportioning valve requiring replacement, from the HCU. INSTALL 1. Wet O-ring seal on new proportioning valve using clean fresh brake fluid. 2. Install proportioning valve in HCU and hand tighten until proportioning is fully installed and 0-ring seal is seated into HCU. Then torque proportioning valve to 40 Nm (30 ft. lbs.). 3. Install brake tube on proportioning valve. Tighten tube nut to 17 Nm (145 inch lbs.) torque. 4. Bleed the base brakes hydraulic system. Refer to Brakes Service and Repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4988 Brake Proportioning/Combination Valve: Service and Repair Without Antilock Brakes Proportioning Valves For Non-ABS Vehicles REMOVE 1. Remove hydraulic brake line from proportioning valve controlling the rear wheel of the vehicle which has premature wheel skid. 2. Then remove the proportioning valve from the rear brake line. INSTALL 1. Install proportioning valve in rear brake line and hand tighten both tube nuts until they are fully seated in proportioning valve. 2. Tighten both brake line tube nuts at the proportioning valve to a torque of 17 Nm (145 in. lbs.). 3. Bleed the affected brake line. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Page 4989 Brake Proportioning/Combination Valve: Tools and Equipment Proportioning Valve Pressure Test Fitting Proportioning Valve Pressure Test Gauge Set GENERAL INFORMATION The new in-line proportioning valves used on this vehicle, require new pressure fittings to test for proper proportioning valve function. The pressure fittings are installed before and after the proportioning valve being tested to verify proportioning valve is maintaining the required hydraulic pressure to the rear wheel brake which it controls. CONDITION If a condition of premature rear wheel skid occurs on a vehicle the proportioning valve should always be tested prior to it being replaced. This is due to the fact that there are conditions other then a faulty proportioning valve which can cause a premature rear wheel skid. TOOLS Testing proportioning valve pressures on a vehicle with or without ABS requires using the same special tools. There are 4 new Pressure Fittings, Special Tool 6805 or equivalent which are to be used for testing the proportioning valves. These same pressure fittings are used if the proportioning valves are either mounted in the HCU, on an antilock equipped vehicle, or in-line on the brake tube on non-antilock equipped vehicles. The pressure gauges used with the pressure test fittings for testing the in-line proportioning valves on both non-ABS and ABS brakes, is the Pressure Gauge Set, Special Tool C-4007-A, or equivalent currently used for testing the combination valve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications Hydraulic Control Unit: Specifications To Mounting Bracket Bolts .................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Bracket To Crossmember Mounting Bolts .......................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications > Page 4993 Hydraulic Control Unit Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications > Page 4994 Hydraulic Control Unit: Service Precautions WARNING: THE ONLY PARTS OF THE HYDRAULIC CONTROL UNIT (HCU) THAT ARE SERVICEABLE ARE THE RELAY BOX, THE PROPORTIONING VALVES, AND THE HCU MOUNTING BRACKET. THE REMAINING COMPONENTS OF THE HYDRAULIC CONTROL UNIT HCU ARE NOT SERVICEABLE ITEMS. NO ATTEMPT SHOULD EVER BE MADE TO REMOVE OR SERVICE ANY OTHER PARTS OF THE HYDRAULIC CONTROL UNIT HCU. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information Hydraulic Control Unit: Description and Operation General Information Hydraulic Control Unit PURPOSE The Hydraulic Control Unit (HCU) is located on the right side of the vehicle, mounted to the front suspension. The HCU is mounted to the front suspension crossmember using a mounting bracket attached to the crossmember, which the HCU is mounted to using 3 isolation bushings. The HCU contains the following components for controlling brakes during Antilock Brake System (ABS) braking: 4 Decay Valves, 4 Shuttle Valves, 2 Fluid Sumps, a Pump/Motor and a relay box. Also attached to the HCU are the rear brake Proportioning Valves and the vehicles 6 hydraulic brake tubes. Decay Solenoids There are 4 decay solenoids, one for each wheel. In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle. In the actuated (decay) position, they provide a fluid path from wheel brakes of the vehicle to the sumps. The Decay solenoids are spring loaded in the released (build) position during normal braking. Shuttle Valves There are 4 Shuttle Valves, one for each wheel. The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized. This places an orifice (restriction) in the line between the pump and the decay solenoid. This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the ABS cycle is complete. When the ABS cycle has been completed the decay solenoids will return to their released position which will equalize the pressure across the Shuttle Valves. When the pressure equalizes, the spring loaded Shuttle Orifice valves will return to the unrestricted position. Fluid Sumps There are two fluid sumps in the HCU, one each for the primary and secondary hydraulic circuits. The fluid sumps temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This fluid is then delivered to the pump to provide build pressure. The typical pressure in the sumps is 50 psi, during ABS operation only. Pump Motor Assembly The HCU contains 2 Pump Assemblies, one each for the primary and secondary hydraulic circuits. Both pumps are driven by a common electric motor which is part of the HCU. The pumps pick up fluid from the sumps to supply build pressure to the brakes during an ABS stop. The motor only runs during an ABS stop and is controlled by the Controller Antilock Brake (CAB) via the Pump/Motor Relay. The Pump/Motor Assembly is not a serviceable item. If it requires service the HCU must be replaced. Relay Box ABX-4 utilizes two relays contained in a relay box mounted to the HCU. The relay box contains a System Relay and a Pump/Motor Relay. A single 10-way connector provides the electrical interface. The relay box is serviceable as an assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4997 Hydraulic Control Unit: Description and Operation Hydraulic Control Unit Decay Solenoids HYDRAULIC CONTROL UNIT DECAY SOLENOIDS There are 4 decay solenoids, one for each wheel. In the released position they provide a fluid path from the Master Cylinder to the wheel brakes of the vehicle. In the actuated (decay) position, they provide a fluid path from wheel brakes of the vehicle to the sumps. The Decay Solenoids are spring loaded in the released (build) position during normal braking. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4998 Hydraulic Control Unit: Description and Operation Hydraulic Control Unit Shuttle Valves HYDRAULIC CONTROL UNIT SHUTTLE VALVES There are 4 Shuttle Valves, one for each wheel. The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized. This places an orifice (restriction) in the line between the pump and the decay solenoid. This restriction provides a controlled build rate to each wheel brake during an ABS stop. The Shuttle Valve will remain in the orificed position until the ABS cycle is complete. When the ABS cycle has been completed the decay solenoids will return to their released position which will equalize the pressure across the Shuttle Valves. When the pressure equalizes, the spring loaded Shuttle Orifice valves will return to the unrestricted position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > General Information > Page 4999 Hydraulic Control Unit: Description and Operation Hydraulic Modulator Circuit Operation CIRCUIT OPERATION Hydraulic Modulator The hydraulic modulator is used for controlling the brake system pressure to the wheels. The modulator is composed of four solenoids. Circuits involved are: B142 for the left front wheel, B143 for the right front wheel, B146 for the left rear wheel, and B148 for the right rear wheel. The solenoids use a common ground on the Z1 circuit. There are two Z1 circuits from the modulator. Both of these grounds terminate at the right frame rail, and are spliced in with the ABS pump motor and the ABS system relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement Hydraulic Control Unit: Service and Repair Hydraulic Control Unit (HCU) Replacement Removal PROCEDURE Ground Cable Attachment At Strut Tower 1. Remove the remote ground cable from the ground stud located on the left strut tower. Correctly Isolated Remote Ground Cable 2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown. This will prevent accidental grounding of the remote ground cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5002 Brake Pedal Holding Tool Installed 3. Using a brake pedal positioning tool such as shown depress brake pedal past its first 1 inch of travel and hold in this position. This will isolate the master cylinder reservoir from the brake hydraulic system, not allowing the brake fluid to drain out of the reservoir. 4. Raise vehicle on jackstands or center on a hoist. 5. Using Mopar, Brake Parts Cleaner or an equivalent, thoroughly clean all surfaces of the Hydraulic Control Unit (HCU). Also, thoroughly clean all brake line tube nut to HCU and proportioning valve connections. Exhaust Pipe Mounting To Exhaust Manifold 6. Remove the entire exhaust system from the vehicle as a complete assembly using following steps. ^ Remove attaching bolts from exhaust pipe at exhaust manifold on engine. Exhaust System Support/Isolators Locations ^ Remove all exhaust system support/isolators from the vehicle's exhaust system. Remove support/isolators from brackets on exhaust system components and leave attached to body of vehicle. ^ Lower exhaust system as a complete assembly away from the underbody of the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5003 Right Side Splash Shield 7. Remove right side engine compartment splash shield from the vehicle. HCU Heat Shield 8. Remove the HCU heat shield from the HCU mounting bracket. Electrical Connections At HCU And Relay Box 9. Disconnect the 6 way connector from the HCU wiring harness and the 10 way connector from the relay box located on the HCU. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5004 Brake Tubes At HCU 10. Remove the brake tube routing clip from the HCU mounting bracket. Then remove the 2 brake tubes coming from master cylinder and the brake tube going to the left front wheel from the HCU ports. Rear Brake Tubes And Right Front Brake Tube At HCU 11. Remove the 2 rear brake tubes from the proportioning valves and the right front brake tube from the outlet port of the HCU. Front Attachment Of HCU To Mounting Bracket 12. Remove bolt attaching the front of the HCU to its mounting bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5005 Rear Attachment Of HCU To Mounting Bracket 13. Remove the 2 bolts attaching the rear of the HCU to its mounting bracket. If vehicle being serviced is equipped with a 2.5L engine, remove the tube as indicated. Removing this tube will make it easier to remove the HCU assembly from the vehicle. Removal Of HCU Assembly From Vehicle 14. Remove HCU from its mounting bracket. Then remove HCU from vehicle out through the exhaust tunnel in the floor pan of the vehicle. Installation PROCEDURE 1. Install the Hydraulic Control Unit (HCU) back in the vehicle and on its mounting bracket using the reverse order of its removal. Rear Attachment Of HCU To Mounting Bracket 2. Install mounting isolators, washers and attaching bolts, mounting the rear of the HCU to the mounting bracket. Do not tighten bolts at this time. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5006 Front Attachment Of HCU To Mounting Bracket 3. Install mounting isolator, washer and attaching bolt, mounting the front of the HCU to the mounting bracket. Do not tighten bolt at this time. 4. Then tighten the 3 HCU mounting bolts to a torque of 28 Nm (248 inch lbs.). Rear Brake Tubes And Right Front Brake Tube At HCU 5. Install the 2 rear brake tubes on the proportioning valves and the right front brake tube in the outlet port of the HCU. Tighten the 3 brake tube nuts to a torque of 20 Nm (180 inch lbs.). Brake Tubes At HCU 6. Install the 2 brake tubes coming from master cylinder and the brake tube to the left front wheel in the HCU ports. Tighten the 3 brake tube nuts to a torque of 20 Nm (180 inch lbs.). Install the brake tube routing clip on the HCU mounting bracket and securely tighten attaching bolt. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5007 Electrical Connections At HCU And Relay Box 7. Install the 6 way connector on the HCU wiring harness and the 10 way connector on the relay box of the HCU. HCU Heat Shield 8. Install the HCU heat shield on the HCU mounting bracket. Install and securely tighten attaching bolt. 9. Install exhaust system in vehicle using the reverse steps of its removal. Right Side Splash Shield 10. Install right side engine compartment splash shield back on the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5008 Ground Cable Attachment At Strut Tower 11. Install the remote ground cable onto the ground stud located on left shock tower. Install the remote ground cable attaching nut and tighten to a torque of 28 Nm (250 inch lbs.). 12. Bleed the base brakes and the ABS brakes hydraulic system. Refer to Antilock Brake System Service and Repair for the proper bleeding procedure. 13. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5009 Hydraulic Control Unit: Service and Repair Relay Box Replacement GENERAL INFORMATION The system relay and pump/motor relay are both serviced together as an assembly with the relay box. The relay box is mounted directly to the Hydraulic Control Unit (HCU). To remove the relay box from the HCU, the HCU requires removal from the vehicle. This is to allow visual access of the relay box to HCU electrical connection. Visual access to this connection is necessary to be sure connection is correctly made when installing the relay box on the HCU. REMOVE 1. Disconnect negative (ground) cable from the battery and isolate the cable. 2. Remove the HCU from the vehicle. Refer to Hydraulic Control Unit Removal, for the required removal procedure for the HCU. Relay Box To HCU Mounting Screws 3. Remove the 2 screws attaching the relay box assembly to the HCU. Remove only the 2 screws mounting the relay box to the HCU. Do not remove the pump motor mounting screws. Relay Box To HCU Electrical Connection 4. Grasp relay box with both hands. Without twisting or rocking, pull relay box away from pump motor housing until connector on relay box unplugs from the pump motor terminal. This is a tight connection, relay box will require a good amount of force to unplug it from the pump motor. 5. Remove relay box from HCU. INSTALL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 5010 Pump Motor To Relay Box Electrical Seal 1. Be sure electrical connector seal is installed in pump motor housing before installing relay box. If electrical connector seal is cracked, brittle or in any way damaged it must be replaced before installing relay box. 2. Position relay box on HCU and carefully align the terminals on the relay box with the terminals on the pump motor. 3. Grasp relay box with both hands. Then without twisting or rocking, push relay box onto the pump motor electrical connector as far as possible by hand. 4. Install and securely tighten the 2 screws attaching the relay box assembly to the HCU. 5. Install the HCU back in the vehicle. Refer to Hydraulic Control Unit Installation, for the required installation procedure for the HCU. 6. Connect the negative (-) ground cable back on the negative post of the battery. 7. Bleed the base brakes and the ABS brakes hydraulic system. Refer to the Antilock Brake System Service and Repair for the proper bleeding procedure. 8. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Mechanical Specifications Brake Master Cylinder: Mechanical Specifications With Antilock Brakes To Vacuum Booster Mounting Nut ..................................................................................................................................................... 28 Nm (250 inch lbs.) Without Antilock Brakes Master Cylinder To Booster Mounting Nuts .......................................................................................................................................... 28 Nm (250 in. lbs.) Brake Tubes To Master Cylinder Ports .................................................................................................................................................. 17 Nm (145 in. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Mechanical Specifications > Page 5015 Brake Master Cylinder: Fluid Type Specifications Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5016 Master Cylinder Fluid Level Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes Brake Master Cylinder: Description and Operation With Antilock Brakes Primary And Secondary Ports Without ABS GENERAL INFORMATION The Bendix ABX-4 Brake System uses a modified Master Cylinder and Power Brake Vacuum Booster assembly. The Master Cylinder primary and secondary outputs go directly to the Hydraulic Control Unit (HCU). This master cylinder is a center valve design. The master cylinder is a two outlet design. All vehicles are equipped with a master cylinder having a bore diameter of 22.2 mm. DESIGN OF MASTER CYLINDER The brake system master cylinder assembly consists of the following components. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and threaded ports with seats for hydraulic brake line connections. The brake fluid reservoir of the master cylinder assembly is made of a see through polypropylene type plastic. On ABS master cylinders, the primary outlet port supply hydraulic pressure to the right front and left rear brakes. The secondary outlet ports supply hydraulic pressure to the left front and right rear brakes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 5019 Brake Master Cylinder: Description and Operation Without Antilock Brakes Primary And Secondary Ports Without ABS GENERAL INFORMATION This vehicle uses 2 differently designed master cylinder assemblies depending on whether the vehicle is or is not equipped with antilock brakes. Proportioning valves are mounted directly in the rear wheel chassis brake tubes. This new style proportioning valve replaces the combination valve used in prior designs. With this new design, the chassis brake tubes connect directly from the master cylinder to the brake flex hose. This vehicle uses a standard compensating port master cylinder. The master cylinder is a 4 outlet design. All vehicles are equipped with a master cylinder having a bore diameter of 22.2 mm. DESIGN OF MASTER CYLINDER The brake system master cylinder assembly consists of the following components. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and threaded ports with seats for hydraulic brake line connections. The brake fluid reservoir of the master cylinder assembly is made of a see through polypropylene type plastic. The primary outlet ports supply hydraulic pressure to the right front and left rear brakes. The secondary outlet ports supply hydraulic pressure to the left front and right rear brakes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 When replacing or overhauling a master cylinder, it is advisable to bleed it before installing it on the car. Bleeding Tubes Attached To Master Cylinder Without ABS Bleeding Master Cylinder PROCEDURE 1. Clamp the master cylinder in a vise. Attach bleeding tubes, Special Tool 6802, or equivalent to the master cylinder outlet ports. Position bleeding Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5022 tubes so the outlets of the bleeding tubes will be below the surface of the brake fluid when reservoir is filled to proper level. 2. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. 3. Using a wooden dowel. Depress push rod slowly, and then allow pistons to return to the released position. Continue to repeat this step several times after no more air bubbles are expelled from bleed tubes to ensure all air is bled from the master cylinder. 4. Remove bleeding tubes from master cylinder outlet ports, plug outlet ports and install fill cap on reservoir. 5. Remove master cylinder from vise and install master cylinder into vehicle. 6. Bleed the entire hydraulic system. Manual Bleeding Air Trapped In Brake System Method For Purging Air From Brake System Bleeder Screw CAUTION: - Before removing the Master Cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. NOTE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5023 - For bleeding the ABS hydraulic system, refer to Hydraulic Control Unit. - Correct bleeding of the brakes hydraulic system without the use of pressure bleeding equipment will require the aid of a helper. BLEEDING BRAKES WITHOUT A PRESSURE BLEEDER The following wheel sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. ^ Left rear wheel ^ Right front wheel ^ Right rear wheel ^ Left front wheel 1. Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. 2. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 3. Open the bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop. 4. Close the bleeder screw. Release the brake pedal only after the bleeder screw is closed. 5. Repeat steps 1 through 3, four or five times at each bleeder screw. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the master cylinder reservoir. It must stay at the proper level so air will not be allowed to re-enter the brake system. 6. Test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5024 Brake Master Cylinder: Service and Repair Master Cylinder Replacement REMOVE Master Cylinder Fluid Level Sensor 1. Remove wiring harness connector from brake fluid level sensor in master cylinder brake fluid reservoir. Master Cylinder Primary And Secondary Ports With ABS Primary And Secondary Ports Without ABS 2. Disconnect the primary and secondary brake tubes from the master cylinder outlet ports. Install plugs at all open brake tube outlets on master cylinder assembly. 3. Using Mopar, Brake Parts Cleaner or an equivalent, clean the area where the master cylinder attaches to the vacuum booster. 4. Remove the 2 nuts attaching the master cylinder to the vacuum booster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5025 CAUTION: When removing the routing clip and brake tubes from the mounting stud, do not bend or kink the chassis brake line tubes. Master Cylinder Mounting To Vacuum Booster 5. Slide the master cylinder straight off its mounting studs on the vacuum booster. INSTALL 1. Position master cylinder assembly on studs of power brake unit, aligning push rod on power brake vacuum booster with piston of master cylinder. CAUTION: When installing the routing clip and brake tubes on the mounting stud, do not bend or kink the chassis brake line tubes. Be sure the chassis brake tubes are routed correctly. The chassis brake tubes can not touch each other or other components or the body of the vehicle. 2. Install the 2 master cylinder to power brake vacuum booster mounting nuts. Tighten both nuts to a torque of 28 Nm (250 in. lbs.). 3. Connect brake tubes to master cylinder primary and secondary ports. Then tighten the tube nuts to a torque of 17 Nm (145 in. lbs.). 4. Install the connector from the vehicle wiring harness on the fluid level sensor in the master cylinder fluid reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5026 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Removing Fluid Reservoir from Master Cylinder NOTE: To replace the master cylinder brake fluid reservoir on this vehicle, it is not necessary to remove the master cylinder from the power brake vacuum booster. 1. Using Mopar, Brake Parts Cleaner or an equivalent, thoroughly clean the master cylinder and brake fluid reservoir. 2. Remove the brake fluid reservoir filler cap. 3. Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir. CAUTION: Do not pry fluid reservoir off master cylinder using a tool, damage to the reservoir or master cylinder can result. 4. Remove brake fluid reservoir from master cylinder by rocking the reservoir from side to side while pulling upward on the fluid reservoir. 5. Remove master cylinder housing to brake fluid reservoir sealing grommets. CAUTION: To ensure a leak proof seal when installing a fluid reservoir, never reuse the original fluid reservoir to master cylinder sealing grommets. 6. Install new master cylinder housing to brake fluid reservoir sealing grommets in master cylinder housing. 7. Lubricate reservoir mounting area with fresh clean brake fluid. Place reservoir in position over grommets. Seat reservoir into grommets using a rocking motion while firmly pressing down on fluid reservoir. 8. Be sure reservoir is positioned properly. 9. Make sure bottom of fluid reservoir touches top of both sealing grommets. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 5027 Brake Master Cylinder: Tools and Equipment Handle C-4171 Special Tools C-4689 Special Tools 6802 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder 97 in.lb Tube Nut 145 in.lb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 5031 Rear Wheel Cylinder (Exploded View) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVE With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. 1. In case of a leak, remove brake shoes (replace if soaked with grease or brake fluid.) 2. Disconnect rear brake flex hose tube from wheel cylinder and remove the flex hose routing bracket from the brake support plate. 3. Remove rear wheel cylinder attaching bolts. Then pull wheel cylinder assembly off brake support plate. INSTALL 1. Apply a small bead of silicone sealer around the mating surface of the wheel cylinder to brake support plate. 2. Install wheel cylinder onto brake support plate. Tighten the attaching bolts to a torque of 11 Nm (97 in. lbs.). 3. Hand start hydraulic brake hose tube fitting to wheel cylinder. Tighten the tube nut to a torque of 17 Nm (145 in. lbs.). 4. Install brake shoes on support plate. Refer to Service and Repair Installation. 5. Install rear brake drum onto rear hub. 6. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 109 - 150 Nm (80 - 110 ft. lbs.). 7. Bleed the entire brake system. 8. Adjust the rear brakes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5034 Wheel Cylinder: Service and Repair Cleaning and Inspection With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5035 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Fig 3 Wheel Cylinder DISASSEMBLE To disassemble the wheel cylinders, proceed as follows: 1. Pry boots away from cylinders and remove. 2. Press IN on one piston to force out opposite piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston that remain in the wheel cylinder. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; DO NOT USE ANY PETROLEUM BASE SOLVENTS. clean thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and pitting. Do not use a rag as lint from the rag will stick to bore surfaces.. 4. 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. ASSEMBLE 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 pistons or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the wheel cylinder cups with Mopar Protect-A-Cup Lubricant. 3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Coat the interior surfaces of the push on boots with the Mopar Protect-A-Cup Lubricant 6. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service Precautions Parking Brake Cable: Service Precautions CAUTION: - Discard output cable retaining clip and tension equalizer after removing it from the park brake output cable. A new tension equalizer and retaining clip is to be used when installing a new rear park brake cable. - A new cable tension equalizer must be installed when replacing a rear park brake cable. The new cable tension equalizer is required to correctly adjust park brake cable tension after installing a new rear park brake cable. - A new retainer must be used when installing the park brake mechanism output cable on the cable tension equalizer. Cable retainer usage is required to ensure output cable can not separate from tension equalizer. NOTE: - The park brake cable routing and routing brackets are different on the right and left side of the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal Parking Brake Cable: Service and Repair Cable Removal NOTE: For servicing of either the left or right rear park brake cable, follow the procedure as listed below. PROCEDURES Center Console Rear Attaching Screws 1. Remove the 2 screws attaching rear of center console assembly to console bracket. Shift Knob Retaining Screw 2. If vehicle is equipped with an automatic transmission remove the shift knob from the shifter. The gear shift knob is attached to the shifter using a set screw. Access to the set screw is from the front of the shift knob and is removed using a 2 mm Allen wrench. Gearshift Knob Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5042 Gearshift Knob Removal Boot Removal 3. If the vehicle is equipped with a manual transmission remove the gearshift knob and shifter boot using the following procedure. ^ Push shifter boot down to expose clips on gear shift knob and roll pin on shifter handle. ^ Pry the clips on the shifter knob away from the roll pin in the shifter handle using a flat blade pry tool. ^ Remove the shifter knob from the shifter handle, by pulling the shifter knob straight up. ^ Remove the shifter boot from the center console. Shifter boot is removed by squeezing the bezel together at the base of the shifter boot and pulling upward on the boot. Center Console Front Attaching Screws (Automatic) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5043 Center Console Attaching Screws (Manual) 4. Remove the 2 screws attaching the front of the center console to the gear selector or shifter. 5. Raise park brake hand lever to the mid-position of its travel. This will allow for the required clearance to remove center console. 6. Remove center console/arm rest from vehicle. 7. Lower park brake lever handle. Park Brake Lever Output Cable Adjustment Nut 8. Loosen adjusting nut on park brake cable output cable. This will take tension off park brake cables, allowing rear park brake cables to be easily removed from tension equalizer. Rear Park Brake Cables At Tension Equalizer 9. Remove the rear park brake cable requiring service, from the park brake cable tension equalizer. 10. Remove rear seat cushion from vehicle. 11. Remove scuff plates from right and left rear door sills. Scuff plates are attached to door sills using clips on bottom of scuff plates. Remove by carefully prying scuff plate retaining clips out of door sills. 12. Fold rear carpeting forward to expose park brake cables. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5044 Park Brake Cable Attachment To Floor Pan 13. Remove the routing clip attaching the rear park brake cables to the floor pan of the vehicle. Compressing Park Brake Cable Retaining Tabs 14. Install the box end of a 1/2 in. wrench over the park brake cable retainer as indicated in. This will compress tabs on park brake cable retainer, allowing cable to be removed from console bracket. From under carpet, grasp park brake cable housing and pull cable straight out of console bracket. 15. Raise vehicle on jackstands or centered on a frame contact type hoist. 16. Remove rear wheel and tire assembly from the side of the vehicle requiring park brake cable service. Rear Brake Drum 17. Remove the rear brake drum from the rear hub/bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5045 Rear Hub/Bearing Dust Cap 18. Remove dust cap from rear hub/ bearing assembly. Hub/Bearing Assembly Retaining Nut 19. Remove the rear hub/bearing assembly retaining nut. 20. Remove the rear hub/bearing assembly from the rear spindle. Park Brake Cable At Actuating Lever 21. Remove the park brake cable from the park brake actuating lever on the trailing brake shoe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5046 Park Brake Cable Removal From Brake Support Plate 22. Remove park brake cable from rear brake support plate. Park brake cable is removed from brake support plate using a 1/2 in. wrench as shown to compress locking tabs on park brake cable retainer. 23. Raise vehicle. NOTE: The park brake cable routing and routing brackets are different on the right and left side of the vehicle. Park Brake Cable Routing Brackets (Right Side) Park Brake Cable Routing Brackets (Left Side) 24. Remove the 2 routing brackets attaching the right hand side or left hand side park brake cable to the frame rail. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5047 Park Brake Cable Removal/Installation At Floor Pan 25. Remove the park brake cable and sealing grommet from the floor pan of the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5048 Parking Brake Cable: Service and Repair Cable Installation PROCEDURES Park Brake Cable Removal/Installation At Floor Pan 1. Install park brake cable into floor pan of vehicle making sure sealing grommet is installed in floor pan as far as possible to insure a proper seal. 2. Install park brake cable into the rear brake support plate. Be sure locking tabs on cable retainer are expanded to ensure park brake cable is securely held in the support plate. NOTE: The park brake cable routing and routing brackets are different on the right and left side of the vehicle. Be sure the correct routing brackets are installed on the correct side of the vehicle. The routing brackets will ensure the correct routing of the park brake cable for the side of the vehicle it is installed on. Park Brake Cable Routing Brackets (Right Side) Park Brake Cable Routing Brackets (Left Side) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5049 3. Install the 2 park brake cable routing brackets on the right or left side rear frame rail. Install and securely tighten routing bracket attaching bolts. Park Brake Cable At Actuating Lever 4. Install the park brake cable on the park brake actuating lever of the trailing brake shoe. Hub/Bearing Assembly Retaining Nut 5. Install hub/bearing assembly on rear spindle. Then install a new rear hub/bearing assembly retaining nut. Torque hub/bearing assembly to spindle retaining nut to 250 Nm (185 ft. lbs.). Rear Hub/Bearing Dust Cap 6. Install hub/bearing assembly dust cap, using a soft faced hammer. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5050 Rear Brake Drum 7. Install rear brake drum on hub/bearing assembly. 8. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in criss cross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). 9. Lower vehicle. 10. Grasp park brake cable to floor pan seal grommet by hand, and pull it into floor pan to ensure seal grommet is fully seated into floor pan. Park Brake Cable Installed In Console Bracket 11. Route park brake cable under carpeting and up to park brake cable hole in console bracket on floor pan. Then install park brake cable into console bracket. Be sure tabs on park brake cable retainer, have expanded out to hold park brake cable in console bracket. Park Brake Cable Attachment To Floor Pan 12. Install the routing bracket holding park brake cables to the floor pan of the vehicle. CAUTION: Discard output cable retaining clip and tension equalizer after removing it from the park brake output cable. A new tension equalizer and retaining clip is to be used when installing a new rear park brake cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5051 Output Cable To Equalizer Retaining Clip 13. Using a screwdriver unlatch the park brake output cable retainer. Then remove cable retainer and park brake cable tension equalizer from park brake lever output cable and discard components. CAUTION: A new cable tension equalizer must be installed when replacing a rear park brake cable. The new cable tension equalizer is required to correctly adjust park brake cable tension after installing a new rear park brake cable. Park Brake Cable Tension Equalizer 14. Install a NEW park brake cable tension equalizer on the park brake lever output cable and rear park brake cables. Cable Retainer Installed On Tension Equalizer CAUTION: A new retainer must be used when installing the park brake mechanism output cable on the cable tension equalizer. Cable retainer usage is required to ensure output cable can not separate from tension equalizer. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5052 15. Install a new park brake lever output cable to tension equalizer retaining clip on tension equalizer. The cable retainer must be closed and securely latched. Park Brake Lever Output Cable Adjustment 16. Cable tension, for the parking brake system is to be correctly adjusted using the following steps. ^ Position park brake lever so it is in the fully released position. ^ Tighten adjusting nut on park brake lever output cable until 12 mm of thread is out past top edge of adjustment nut. ^ Actuate the park brake lever to its fully applied position (21 clicks) 1 time and then reposition lever to its fully released position. NOTE: Actuating the park brake lever to its fully applied position 1 time after tightening the adjustment nut will yield (stretch) the bent nail portion of the tension equalizer approximately 1/4 inch. This process will correctly set the park brake cable tension. 17. Check the rear wheels of the vehicle with the park brake lever fully released. They should rotate freely without dragging. 18. After the park brake cable tension has been properly adjusted, check for free play in park brake lever. Park brake hand lever should feel firm at all clicks, with a maximum of 21 clicks of lever travel possible. 19. Install the center console back in the vehicle. Center Console Front Attaching Screws (Automatic) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5053 Center Console Attaching Screws (Manual) 20. Install the 2 screws attaching the front of the center console. Center Console Rear Attaching Screws 21. Install screws attaching rear of center console assembly to console bracket. 22. Install the shifter boot or PRNDL plate back in the center console. Shift Knob Retaining Screw Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 5054 Gearshift Knob Removal 23. Install the shift knob on the shifter. 24. Install rear carpeting. 25. Install both rear door sill plate scuff moldings, by snapping them onto rear door sills. 26. Install lower rear seat cushion. Be sure lower seat cushion is fully installed in retainers on floor pan of vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service Precautions Parking Brake Lever: Service Precautions CAUTION: - Discard output cable retaining clip after removing it from park brake cable tension equalizer. Retainer is not to be re-used, a new retainer is to be installed when attaching output cable to tension equalizer. - A new cable tension equalizer must be installed when replacing the park brake mechanism. The new cable tension equalizer is required to correctly adjust park brake cable tension after installing park brake mechanism. - A new park brake lever output cable retainer must be used when installing output cable on cable tension equalizer. Cable retainer usage is required to ensure output cable can not separate from tension equalizer. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal Parking Brake Lever: Service and Repair Parking Brake Lever Removal With Automatic Transaxle Park Brake Lever Mechanism Output Cable PARK BRAKE LEVER OUTPUT CABLE On this vehicle, the park brake lever output cable is not replaceable as a separate component of the park brake lever. Never attempt to repair the park brake output cable in any manner. PROCEDURE Center Console Rear Attaching Screws 1. Remove the 2 screws attaching rear of center console assembly to console bracket. 2. Remove the shift knob from the shifter. The gear shift knob is attached to the shifter using a set screw. Access to the set screw is from the front of the shift knob and is removed using a 2 mm Allen wrench. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5060 Center Console Front Attaching Screws (Automatic) 3. Remove the 2 screws attaching the front of the center console to the gear selector. 4. Raise the park brake hand lever to approximately the half way point of its total travel. This will allow for the required clearance to remove the center console. 5. Remove the center console/arm rest from the vehicle. 6. Lower park brake lever handle. Park Brake Lever Output Cable Adjustment Nut 7. Loosen adjusting nut on park brake lever output cable. This will take tension off output cable, allowing it to be easily removed from tension equalizer. CAUTION: Discard output cable retaining clip after removing it from park brake cable tension equalizer. Retainer is not to be re-used, a new retainer is to be installed when attaching output cable to tension equalizer. Output Cable To Equalizer Retaining Clip 8. Using a screwdriver unlatch the park brake output cable retainer. Then remove cable retainer from park brake cable tension equalizer. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5061 9. Remove the park brake cable tension equalizer from the park brake lever output cable. Wiring Harness Connection To Ground Switch 11. Remove the electrical connector from the ground switch on the park brake lever mechanism. Wiring Harness 12. Unclip the wiring harness from the park brake mechanism bracket. Wiring harness is attached to bracket using 2 routing clips pushed through holes in the top of the bracket. Park Brake Lever Bracket Mounting 13. Remove the 4 bolts attaching the park brake mechanism bracket. 14. Remove the park brake mechanism from the vehicle. With Manual Transaxle Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5062 Park Brake Lever Mechanism Output Cable PARK BRAKE LEVER OUTPUT CABLE On this vehicle, the park brake lever output cable is not replaceable as a separate component of the park brake lever. Never attempt to repair the park brake output cable in any manner. PROCEDURE Center Console Rear Attaching Screws 1. Remove the 2 screws attaching rear of center console assembly to console bracket. Shift Knob Retaining Screw 2. Remove the gearshift knob and shifter boot using the following procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5063 Gearshift Knob ^ Push shifter boot down to expose chips on gear-shift knob and roll pin on shifter handle. ^ Pry the clips on the shifter knob away from the roll pin in the shifter handle using a flat blade pry tool. Gearshift Knob Removal ^ Remove the shifter knob from the shifter handle, by pulling the shifter knob straight up. Boot Removal ^ Remove the shifter boot from the center console. Shifter boot is removed by squeezing the bezel together at the base of the shifter boot and pulling upward on the boot. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5064 Center Console Front Attaching Screws (Automatic) Center Console Attaching Screws (Manual) 3. Remove the 2 screws attaching the front of the center console to the gear selector or shifter. 4. Raise the park brake hand lever to approximately the half way point of its total travel. This will allow for the required clearance to remove the center console. 5. Remove the center console/arm rest from the vehicle. 6. Lower park brake lever handle. Park Brake Lever Output Cable Adjustment Nut 7. Loosen adjusting nut on park brake lever output cable. This will take tension off output cable, allowing it to be easily removed from tension equalizer. CAUTION: Discard output cable retaining clip after removing it from park brake cable tension equalizer. Retainer is not to be re-used, a new retainer is to be installed when attaching output cable to tension equalizer. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5065 Output Cable To Equalizer Retaining Clip 8. Using a screwdriver unlatch the park brake output cable retainer. Then remove cable retainer from park brake cable tension equalizer. 9. Remove the park brake cable tension equalizer from the park brake lever output cable. Wiring Harness Connection To Ground Switch 10. Remove the electrical connector from the ground switch on the park brake lever mechanism. Wiring Harness 11. Unclip the wiring harness from the park brake mechanism bracket. Wiring harness is attached to bracket using 2 routing clips pushed through holes in the top of the bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5066 Park Brake Lever Bracket Mounting 12. Remove the 4 bolts attaching the park brake mechanism bracket. 13. Remove the park brake mechanism from the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5067 Parking Brake Lever: Service and Repair Parking Brake Lever Installation With Automatic Transaxle PROCEDURE Park Brake Lever Bracket Mounting 1. Place the park brake mechanism on the console bracket. Install the 4 bolts mounting the park brake mechanism to the console bracket. Tighten the 4 mounting bolts to a torque of 28 Nm (250 in. lbs.). Wiring Harness 2. Install the wiring harness on the park brake mechanism bracket. Wiring Harness Connection To Ground Switch Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5068 3. Install the electrical connector on the ground switch of the park brake lever mechanism. CAUTION: A new cable tension equalizer must be installed when replacing the park brake mechanism. The new cable tension equalizer is required to correctly adjust park brake cable tension after installing park brake mechanism. Park Brake Cable Tension Equalizer 4. Install a NEW park brake cable tension equalizer on the park brake lever output cable and rear park brake cables. CAUTION: A new park brake lever output cable retainer must be used when installing output cable on cable tension equalizer. Cable retainer usage is required to ensure output cable can not separate from tension equalizer. Cable Retainer Installed On Tension Equalizer 5. Install a new park brake lever output cable to tension equalizer retaining clip on tension equalizer. The cable retainer must be closed and securely latched. Park Brake Lever Output Cable Adjustment Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5069 6. Cable tension, for the parking brake system is to be correctly adjusted using the following steps. a) Position park brake lever so it is in the fully released position. b) Tighten adjusting nut on park brake lever output cable until 12 mm of thread is out past top edge of adjustment nut. c) Actuate the park brake lever to its fully applied position (22 clicks) 1 time and then reposition lever to its fully released position. Actuating the park brake lever to its fully applied position 1 time after tightening the adjustment nut will yield (stretch) the bent nail portion of the tension equalizer approximately 1/4 inch. This process will correctly set the park brake cable tension. 7. Check the rear wheels of the vehicle with the park brake lever fully released. They should rotate freely without dragging. 8. After the park brake cable tension has been properly adjusted, check for free play in park brake lever. Park brake hand lever should feel firm at all clicks, with a maximum of 22 clicks of lever travel possible. 9. Install the center console back in the vehicle. Center Console Front Attaching Screws (Automatic) 10. Install the 2 screws attaching the front of the center console to the forward console. Center Console Rear Attaching Screws 11. Install screws attaching rear of center console assembly to console bracket. 12. Install the PRNDL plate back in the center console. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5070 Shift Knob Retaining Screw 13. Install the shift knob on the shifter. With Manual Transaxle PROCEDURE Park Brake Lever Bracket Mounting 1. Place the park brake mechanism on the console bracket. Install the 4 bolts mounting the park brake mechanism to the console bracket. Tighten the 4 mounting bolts to a torque of 28 Nm (250 in. lbs.). Wiring Harness 2. Install the wiring harness on the park brake mechanism bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5071 Wiring Harness Connection To Ground Switch 3. Install the electrical connector on the ground switch of the park brake lever mechanism. CAUTION: A new cable tension equalizer must be installed when replacing the park brake mechanism. The new cable tension equalizer is required to correctly adjust park brake cable tension after installing park brake mechanism. Park Brake Cable Tension Equalizer 4. Install a NEW park brake cable tension equalizer on the park brake lever output cable and rear park brake cables. CAUTION: A new park brake lever output cable retainer must be used when installing output cable on cable tension equalizer. Cable retainer usage is required to ensure output cable can not separate from tension equalizer. Cable Retainer Installed On Tension Equalizer 5. Install a new park brake lever output cable to tension equalizer retaining clip on tension equalizer. The cable retainer must be closed and securely latched. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5072 Park Brake Lever Output Cable Adjustment 6. Cable tension, for the parking brake system is to be correctly adjusted using the following steps. a) Position park brake lever so it is in the fully released position. b) Tighten adjusting nut on park brake lever output cable until 12 mm of thread is out past top edge of adjustment nut. c) Actuate the park brake lever to its fully applied position (22 clicks) 1 time and then reposition lever to its fully released position. Actuating the park brake lever to its fully applied position 1 time after tightening the adjustment nut will yield (stretch) the bent nail portion of the tension equalizer approximately 1/4 inch. This process will correctly set the park brake cable tension. 7. Check the rear wheels of the vehicle with the park brake lever fully released. They should rotate freely without dragging. 8. After the park brake cable tension has been properly adjusted, check for free play in park brake lever. Park brake hand lever should feel firm at all clicks, with a maximum of 22 clicks of lever travel possible. 9. Install the center console back in the vehicle. Center Console Attaching Screws (Manual) 10. Install the 2 screws attaching the front of the center console to the forward console. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Parking Brake Lever Removal > Page 5073 Center Console Rear Attaching Screws 11. Install screws attaching rear of center console assembly to console bracket. 12. Install the shifter boot back in the center console. Gearshift Knob Removal 13. Install the shift knob on the shifter. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications EGR Tube Mounting Bolts ................................................................................................................... ................................................... 11 Nm (95 in. lbs.) Master Cylinder Mounting Nuts ............................................................................................................................................................ 28 Nm (250 in. lbs.) Power Brake Vacuum Booster Mounting Nuts ...................................................................................................................................... 29 Nm (250 in. lbs.) Speed Control Servo Mounting Nuts ......................................................................................................................................................... 6 Nm (55 in. lbs.) Throttle Body Attaching Bolts ..................................................................................... .......................................................................... 22 Nm (200 in. lbs.) Tube Nuts ................................. .............................................................................................................................................................. 17 Nm (145 in. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5081 Vacuum Brake Booster: Service Precautions CAUTION: When installing the routing clip and brake tubes on the mounting stud, do not bend or kink the chassis brake line tubes. Be sure the chassis brake tubes are routed correctly. The chassis brake tubes can not touch each other or other components or the body of the vehicle. NOTE: The vacuum booster assembly is not a repairable part and must be replaced as a complete unit if it is found to be faulty in any way. The vacuum brake booster check valve is not repairable but can be replaced as a component of the vacuum booster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5082 Vacuum Brake Booster: Description and Operation Vacuum Booster Identification Vacuum Booster Assembly GENERAL INFORMATION All vehicles use a 205 mm tandem diaphragm vacuum brake booster. The vacuum booster though, may be unique for the type of brake system the vehicle is equipped with. For this reason, if the power brake vacuum booster requires replacement, be sure it is replaced with the correct part for the type of brake system that the vehicle is equipped with. The vacuum booster can be identified if required, by the tag attached to the body of the vacuum booster. This tag contains the following information: The production part number of the vacuum booster, the date it was built, and who manufactured it. NOTE: The vacuum booster assembly is not a repairable part and must be replaced as a complete unit if it is found to be faulty in any way. The vacuum booster check valve is not repairable but can be replaced as a component of the vacuum booster. PURPOSE The vacuum booster reduces the amount of force required by the driver to obtain the necessary hydraulic pressure to stop the vehicle. The vacuum booster is vacuum operated. The vacuum is supplied from the intake manifold on the engine through the power brake booster check valve. As the brake pedal is depressed, the vacuum boosters input rod moves forward. This opens and closes valves in the vacuum booster, allowing atmospheric pressure to enter on one side of a diaphragm. Engine vacuum is always present on the other side. This difference in pressure forces the output rod of the vacuum booster out against the primary piston of the master cylinder. As the pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system. Different systems and engine combinations require different vacuum hose routings. LOCATION The vacuum booster assembly mounts on the engine side of the dash panel. It is connected to the brake pedal by the input push rod. A vacuum line connects the vacuum booster to the intake manifold. The master cylinder is bolted to the front of the vacuum booster assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal Vacuum Brake Booster: Service and Repair Removal PROCEDURE Ground Cable Attachment At Strut Tower 1. Remove the remote ground cable from the ground stud located on the left shock tower. Correctly Isolated Remote Ground Cable 2. Correctly isolate remote ground cable when servicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown. This will prevent accidental grounding of the remote ground cable. Engine Air Intake System Components 3. Remove the Positive Crankcase Ventilation PCV hose from the air chamber located on the front of the intake manifold. Remove bolt attaching the air chamber to the intake manifold. Then unlatch lid of air cleaner from air cleaner housing and loosen clamp attaching air inlet hose to throttle body. Remove the air cleaner lid, air inlet hose and air chamber as an assembly from the engine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5085 Throttle Body Attachment To Intake Manifold 4. Remove the throttle cable and if equipped the speed control cable from the throttle body. Remove the vacuum hose from the throttle body. Remove the wiring harness connectors from AIS motor and the Throttle Position Sensor on the throttle body. Then, remove the 4 bolts attaching the throttle body to the intake manifold and remove it from intake manifold. 5. Without removing cables from bracket, remove the throttle and speed control cable mounting bracket from the intake manifold. EGR Tube Attachment To Intake Manifold And EGR Valve 6. Remove the Exhaust Gas Recirculation EGR tube from the intake manifold and EGR valve. Speed Control Servo Attachment To Strut Tower 7. If equipped, remove the vehicle's wiring harness connector from the speed control servo. Remove the 2 speed control servo mounting bracket to strut tower attaching nuts. Without removing speed control cable from servo, move speed control servo out of the way. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5086 Primary And Secondary Brake Tubes With Antilock Brakes Primary And Secondary Ports Without ABS 8. Remove the primary and secondary brake tubes from the Master Cylinder Assembly. Master Cylinder Brake Fluid Level Sensor 9. Remove the vehicle's wiring harness connector from the master cylinder brake fluid level sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5087 Master Cylinder Mounting To Vacuum Booster 10. Remove the 2 nuts attaching the master cylinder assembly to the power brake vacuum booster. Then remove the master cylinder assembly from the power brake vacuum booster. Purge Control Solenoid 11. Remove the vacuum harness connector and electrical connector from the purge solenoid. Remove bracket and purge solenoid as an assembly from the vehicle. Transaxle Dipstick Tube 12. Remove dipstick tube attaching bolt. Then remove the dipstick tube and dipstick as an assembly from the transaxle. 13. Remove the vacuum hoses from the check valve located on the power brake vacuum booster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5088 Input Rod Retaining Pin 14. Locate the power brake vacuum booster input rod to brake pedal attachment under instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. Replace only with a new retaining clip when assembled. Power Brake Booster Mounting 15. Remove the 4 nuts attaching power brake vacuum booster to dash panel. Nuts are accessible from under dash panel in area of the steering column and pedal bracket assembly. Power Brake Vacuum Booster Removal 16. Slide power brake vacuum booster straight forward until mounting studs clear dash panel. Then lift power brake vacuum booster strait up to remove it from the vehicle. CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced ONLY as a complete assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5089 Vacuum Brake Booster: Service and Repair Installation PROCEDURE 1. Position power brake booster onto dash panel. Power Brake Booster Mounting 2. Install and torque the 4 power brake vacuum booster mounting nuts to 29 Nm (250 in. lbs.) torque. 3. Using Lubriplate, or an equivalent, coat the surfaces of the brake pedal pin that contact the power brake vacuum booster input rod. 4. Connect power brake vacuum booster input rod to brake pedal pin and install a NEW retaining clip. Use only a new retainer clip DO NOT USE the old clip. Transaxle Dipstick Tube 5. Install the dipstick tube in transaxle. Install dipstick tube attaching bolt and securely tighten. 6. Install the vacuum hoses on the check valve in the power brake vacuum booster. Purge Control Solenoid Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5090 7. Position purge control solenoid on left front strut tower and install and securely tighten attaching bolt. Then correctly route and install the vacuum harness connector and electrical connector on the purge control solenoid. 8. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod. Master Cylinder Mounting To Vacuum Booster 9. Install the 2 master cylinder to power brake unit mounting nuts. Tighten the 2 mounting nuts to a torque of 28 Nm (250 in. lbs.). Primary And Secondary Brake Tubes With Antilock Brakes Primary And Secondary Ports Without ABS 10. Install the primary and secondary brake tubes in the master cylinder assembly outlet ports. Tighten all tube nuts to a torque of 17 Nm (145 in. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5091 Master Cylinder Brake Fluid Level Sensor 11. Install the vehicle's wiring harness connector on the master cylinder brake fluid level sensor. Speed Control Servo Attachment To Strut Tower 12. If equipped, install speed control servo on the mounting studs in the left strut tower. Install the 2 speed control servo bracket mounting nuts. Tighten the 2 mounting nuts to a torque of 6 Nm (55 in, lbs.). Install electrical connector on speed control servo. EGR Tube Attachment To Intake Manifold And EGR Valve 13. Install the EGR tube with NEW gaskets on the intake manifold and EGR valve. Install the 4 mounting bolts and tighten to a torque of 11 Nm (95 in. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5092 Throttle Body Attachment To Intake Manifold 14. Install the throttle body and a NEW gasket on the intake manifold. Install the 4 throttle body attaching bolts and tighten to a torque of 22 Nm (200 in. lbs.). 15. Install the vacuum hose on the throttle body. Install the wiring harness connectors on the AIS motor and the Throttle Position Sensor located on the throttle body. 16. Install the mounting bracket for the throttle cable and speed control cable onto the intake manifold and securely tighten the mounting bolts. 17. Install the throttle cable, and if equipped, the speed control cable on the cam of the throttle body assembly. Engine Air Intake System Components 18. Install the air cleaner lid, air inlet hose and air chamber as an assembly on the engine. Latch lid of air cleaner to air cleaner housing. Securely tighten the clamp attaching the air inlet hose to the throttle body. Install and securely tighten the bolt attaching the air chamber to the intake manifold. Ground Cable Attachment At Strut Tower 19. Install the remote ground cable on the ground stud located on the left strut tower. Install and securely tighten the ground cable attaching nut. 20. Check brake light switch for correct adjustment. If required, adjust stop lamp switch as necessary. Refer to Lighting and Horns Brake Light Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 5093 Switch. 21. Road test vehicle to ensure proper operation of the vehicles brake system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations System Relay And Pump Motor Relay Box Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay ABS Main Relay: Description and Operation ABS System Relay CIRCUIT OPERATION The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor, and terminates at the right frame rail. when the system is operating normally, power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the right frame rail. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the A20 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay > Page 5100 ABS Main Relay: Description and Operation ABS System Relays System Relay And Pump Motor Relay Box SYSTEM RELAY The main purpose of the system relay is to put the Antilock Brake System (ABS) into a stand-by mode for ABS operation. The System Relay is energized by the Controller Antilock Brake (CAB) shortly after the ignition switch is turned on. When Energized - by the CAB, the System Relay turns off the ABS warning lamp and provides 12 volts to the CAB. This voltage can then be used by the CAB to energize the Decay Solenoids during ABS braking. When energized, the System Relay also provides the Pump/Motor Relay coil with 12 volts. The ground path to the Pump/Motor Relay is completed by the CAB during ABS braking. When De-energized - the ABS warning lamp is illuminated, voltage to the Decay Solenoids is cut off, and the Pump/Motor Relay is prevented from energizing. Typically, the System Relay is de-energized by the CAB when a fault is detected that requires turning ABS off. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description Brake Fluid Pump Relay: Description and Operation Description System Relay And Pump Motor Relay Box PURPOSE Pump/Motor power is supplied by the Pump/Motor Relay. The pump motor relay is also part of the relay box mounted to the Hydraulic Control Unit (HCU). If pump/motor relay replacement is required, it is also only serviced by the replacement of the relay box assembly. FUNCTION Voltage for the 12 volt side of the relay coil is provided by the System Relay. The ground path through the relay coil is completed by the Controller Antilock Brake (CAB) during Antilock Brake System (ABS) braking. The relay contacts are closed when the relay is energized. This provides 12 volts to the pump/motor as needed during ABS braking. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description > Page 5105 Brake Fluid Pump Relay: Description and Operation Circuit Operation CIRCUIT OPERATION The ABS pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B120 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B10 from the relay box powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Controller Antilock Brake Location CAB 60-Way Wiring Harness Connector The CAB is located in the right front corner of the engine compartment. It is mounted to the vehicle using an integral mounting bracket, which is attached by 2 bolts, to the inner fender and the front crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5109 Electronic Brake Control Module: Description and Operation Controller Antilock Brake Location PURPOSE The Controller Antilock Brakes (CAB) is a microprocessor based device which monitors the ABS system during normal braking and controls it when in an ABS stop. The CAB is mounted in the right front corner of the engine compartment using an integral mounting bracket to attach it to the inner fender. The CAB uses a 60 way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the Run or ON position. NOTE: The CAB is not on the Chrysler Collision Detection (CCD) bus. THE PRIMARY FUNCTIONS OF THE CAB - Detect wheel locking tendencies. - Control fluid modulation to the brakes while in ABS mode. - Monitor the system for proper operation. - Provide communication to the DRB scan tool while in diagnostic mode. The CAB Continuously Monitors - the speed of each wheel through the signals generated at the Wheel Speed Sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABS System Is Constantly Monitored - by the CAB for proper operation. If the CAB detects a fault, it will turn on the Amber ABS Warning Lamp and disable the ABS braking system. The normal Non ABS braking system will remain operational. The CAB Contains A Self-diagnostic Program - which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected. Faults are then stored in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB and displayed through the DRB scan tool. These fault messages will remain in the CAB memory even after the ignition has been turned off. The fault messages can be cleared by using the DRB scan tool, or they will be automatically cleared from the memory after a minimum of 3500 vehicle miles are accumulated. CONTROLLER ANTILOCK BRAKE INPUTS - Four wheel speed sensors. - Stop lamp switch. - Ignition switch. - System relay voltage. - Ground. - Pump/Motor Relay Monitor. - Diagnostics Communications. CONTROLLER ANTILOCK BRAKE OUTPUTS - Decay Solenoids. - ABS warning lamp. - System relay actuation. - Diagnostic communication (Single line ISOK). - Pump motor relay actuation. - Brake Lamp (Low Fluid/Pressure). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5110 Electronic Brake Control Module: Service and Repair Controller Antilock Brake Location REMOVE 1. Turn vehicle ignition off. CAB 60-Way Wiring Harness Connector 2. Disconnect the wiring harness 60 way connector from the Controller Antilock Brake Module (CAB). Verify that the vehicle ignition is off before removing the 60 way connector. CAB Bracket To Engine Compartment Mounting 3. Remove the 2 bolts attaching the CAB mounting bracket to inner fender and front upper crossmember. 4. Remove the CAB from the vehicle. INSTALL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5111 1. Install the CAB and the mounting bracket assembled, on the right inner fender of the vehicle. 2. Install the 2 bolts mounting the CAB bracket to the vehicle. Tighten both mounting bolts to a torque of 9 Nm (75 inch lbs.). 3. Install 60-way wiring harness connector into the CAB 60-way connector by hand until seated as far as possible. Then use CAB connector retaining bolt to fully seat wiring harness connector into the CAB. 4. Tighten the 60-way connector retaining bolt to a torque of 4 Nm (35 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations Master Cylinder Fluid Level Sensor Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 5116 Brake Fluid Level Switch: Service and Repair GENERAL INFORMATION The master cylinder or brake fluid reservoir does not have to be removed from vehicle for replacement of the brake fluid level sensor. Master Cylinder Fluid Level Sensor 1. Remove wiring harness connector from brake fluid reservoir level sensor. Brake Fluid Level Switch Retaining Tabs 2. Compress retaining tabs on end of brake fluid level switch. Removing/Installing Fluid Reservoir Level Switch 3. While compressing retaining tabs, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Correctly align the replacement level switch with its mounting hole in the brake fluid reservoir. Push switch into fluid reservoir until retaining tabs are fully expanded on opposite side of fluid reservoir. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Switch <--> [Brake Fluid Level Sensor/Switch] > Component Information > Locations > Page 5117 5. Install the wiring harness connector onto the brake fluid level switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5128 39 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5129 43 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5130 45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5131 47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5132 51 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5133 55 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5134 57 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5135 59 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5136 63 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5137 67 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5138 69 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5139 71 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5140 173 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5141 177 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5142 179 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5143 181 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5144 187 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5145 191 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5146 193 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5147 195 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5148 201 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5149 205 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5150 207 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5151 209 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5152 256 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5153 Wheel Speed Sensor: Specifications Front Rear Clearance Minimum Clearance 0.014 in 0.016 in Maximum Clearance 0.047 in 0.047 in Runout 0.006 in 0.006 in Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5154 Wheel Speed Sensor: Service Precautions NOTE: - Proper installation of the Wheel Speed Sensor Cables is critical to continued system operation. Be sure that cables are installed, routed and clipped properly. Failure to install speed sensor cables as in the on car service section of this manual, may result in contact with moving parts or over extension of cables, resulting in an open circuit. CAUTION: - If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. - When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5155 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor PURPOSE One Wheel Speed Sensor (WSS) is located at each wheel, and sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a Toothed Sensor Ring (Tone Wheel) passes the stationary magnetic WSS. The CAB converts the AC signal generated at each wheel into a digital signal. OPERATION If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. ASSEMBLY AND LOCATION The front Wheel Speed Sensor is attached to a boss in the steering knuckle. The tone wheel is part of the outboard constant velocity joint. The rear Wheel Speed Sensor on rear drum brake applications is mounted to the rear brake support plate and the rear tone wheel is an integral part of the rear wheel hub and bearing assembly. SERVICE INDIVIDUALLY The four Wheel Speed Sensors are serviced individually. The front Tone Wheels are serviced as an assembly with the outboard constant velocity joint. The rear Tone Wheels are serviced as an assembly with the rear hub and bearing assembly. CORRECT OPERATION DEPENDENT ON ACCURATE SIGNALS Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5156 Wheel Speed Sensor: Testing and Inspection CAREFUL INSPECTION Carefully inspect tone wheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tone wheels should show no evidence of contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive Runout - of the tonewheel can cause erratic wheel speed sensor signals. Refer to Tone-wheel Runout under Specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect For Looseness - on their mounting surfaces. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. See: Specifications Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Removal PROCEDURE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Speed Sensor Cable Routing Brackets 3. Remove the speed sensor cable routing bracket from the steering knuckle. Remove the wiring harness sealing grommet retainer and speed sensor routing bracket from the inner fender. Wheel Speed Sensor Connection To Vehicle Wiring Harness 4. Remove speed sensor sealing grommet from the inner fender. Then unplug the speed sensor cable from the vehicle wiring harness. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5159 Speed Sensor Head Attachment To Steering Knuckle 5. Remove bolt attaching the speed sensor head to the steering knuckle. Then remove speed sensor head from steering knuckle. CAUTION: If speed sensor head locating pin has seized to the steering knuckle, do not attempt to remove speed sensor head by grasping with pliers and turning. This will damage the speed sensor head. Use only the following procedure. Speed Sensor Head Removal From Steering Knuckle 6. If speed sensor head can not be removed from steering knuckle by hand, the locating pin on the speed sensor head has seized to the steering knuckle do to corrosion. Remove speed sensor head from steering knuckle using the following procedure. Remove disc brake caliper from steering knuckle, and remove brake rotor from hub/bearing assembly Then insert a pin punch through hole in front steering knuckle and tap speed sensor head locating pin out of steering knuckle. Installation PROCEDURE CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cable, resulting in an open circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5160 Wheel Speed Sensor Connection To Vehicle Wiring Harness 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. Speed Sensor Cable Routing Brackets 2. Install the speed sensor cable assembly grommet into the front inner fender. Install speed sensor cable grommet retainer/routing bracket on the inner fender of the vehicle and install and securely tighten attaching bolt. Correct Front Wheel Speed Sensor Cable Routing CAUTION: When installing the wheel speed sensor cable routing bracket on the steering knuckle, the speed sensor cable must be looped toward the shock absorber. If speed sensor cable is not routed in this direction it will rub against the tire or wheel, damaging the speed sensor cable. 3. Install the speed sensor cable routing bracket on the steering knuckle. Install and tighten routing bracket mounting bolt to a torque of 12 Nm (105 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5161 Installing Speed Sensor Head In Steering Knuckle 4. Install speed sensor head on steering knuckle. When installing speed sensor head on steering knuckle, apply a small amount of grease on speed sensor locating pinch Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pinch Install the speed sensor head attaching screw and tighten to a torque of 6 Nm (55 inch lbs.). 5. Install the wheel and tire assembly on vehicle. 6. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5162 Wheel Speed Sensor: Service and Repair Rear Removal PROCEDURE Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 1. Unplug the speed sensor cable connector from the vehicle wiring harness. Access for speed sensor cable to vehicle wiring harness connection is in the trunk of the vehicle. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove the rear tire and wheel assembly from the vehicle. Rear Speed Sensor Cable Attachment To Body 4. Remove speed sensor cable sealing grommet retainer from the rear frame rail of the vehicle. Then remove speed sensor cable sealing grommet and cable from hole in body of vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5163 Speed Sensor Cable Attachment To Rear Suspension 5. Remove speed sensor routing clips from the rear upper control arm and brake flex hose routing bracket. Rear Speed Sensor Head Attachment To Brake Support Plate 6. Remove the rear speed sensor head from the rear brake support plate. Installation PROCEDURE CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. Rear Speed Sensor Head Attachment To Brake Support Plate 1. Install speed sensor head into brake support plate. 2. Install wheel speed sensor attaching bolt. Tighten the speed sensor head attaching bolt to 8 Nm (75 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5164 Speed Sensor Cable Attachment To Rear Suspension 3. Install speed sensor cable routing clips on the brake flex hose bracket and the bracket on the upper control arm. Install and securely tighten the routing clip attaching bolts. 4. Install connector end of speed sensor cable through hole in inner fender and into trunk of vehicle. Rear Speed Sensor Cable Attachment To Body 5. Install speed control sealing grommet into hole in inner fender. Install the sealing grommet retainer and attaching bolt on rear frame rail. Securely tighten retainer attaching bolt. 6. Install the tire and wheel assembly on vehicle. 7. Lower vehicle. Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 8. Plug speed sensor cable connector into vehicle wiring harness. Install foam sleeve back over the speed sensor cable to vehicle wiring harness connection to prevent connector from rattling against body of vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5165 9. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service Precautions > Page 5171 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located on the rear side of the front bumper beam. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the Powertrain Management/Computers and Control Systems/Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: 1. Disconnect the sensor from the engine harness. 2. Attach ohmmeter leads to the wire terminals of the sensor. 3. At room temperature of 25 °C (75 - 80°F), an ohmmeter reading of 9 K to 11 K ohms should be observed. 4. If reading is above or below the specification, replace the sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 5174 Battery Temperature Sensor: Service and Repair REMOVAL 1. Raise vehicle on host. 2. Remove screw from sensor. 3. Disconnect electrical connector from sensor. INSTALLATION 1. Connect electrical connector to sensor. 2. Install screw and tighten. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5184 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5185 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5186 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5187 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5188 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5189 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5190 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5191 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5192 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5193 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5194 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5195 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5201 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5202 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5203 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5204 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5205 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5206 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5207 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5208 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5209 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5210 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5211 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5212 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5213 Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5214 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start Lock Cylinder Retaining Tab REMOVAL 1. Disconnect negative cable from auxillary jumper terminal -- on driver's side strut tower. 3. Remove upper steering column shroud. 3. Pull lower shroud down far enough to access lock cylinder retaining tab. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to RUN position (retaining tab on lock cylinder can be depressed). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5215 Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the RUN position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the OFF position. Remove the key. 5. Install steering column shrouds. 5. Connect negative cable to auxillary battery terminal on shock tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5220 Starter Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5221 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5222 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5223 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5224 Starter Relay: Testing and Inspection Starter Relay WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED. Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Service Precautions Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Service Precautions > Page 5229 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Battery Temperature Sensor The sensor is located on the rear side of the front bumper beam. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the Powertrain Management/Computers and Control Systems/Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: 1. Disconnect the sensor from the engine harness. 2. Attach ohmmeter leads to the wire terminals of the sensor. 3. At room temperature of 25 °C (75 - 80°F), an ohmmeter reading of 9 K to 11 K ohms should be observed. 4. If reading is above or below the specification, replace the sensor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 5232 Battery Temperature Sensor: Service and Repair REMOVAL 1. Raise vehicle on host. 2. Remove screw from sensor. 3. Disconnect electrical connector from sensor. INSTALLATION 1. Connect electrical connector to sensor. 2. Install screw and tighten. 3. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications Generator: Specifications Minimum Test Amps ............................................................................................................................ ....................................... 74 amps @ 2500 ± 20 rpm Voltage Output ..................................................................................................................................... ................................................................ 15V ± 0.3V Field Current ........................................................................................................................................ ...................................................... 5 amps ± 0.1 amp Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5237 Generator: Description and Operation SYSTEM OPERATION 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5238 Generator: Service and Repair REMOVAL Remove Battery Cable At Shock Tower 1. Disconnect battery negative cable from remote negative terminal on shock tower. 2. Unplug field circuit from generator. Wiring Connections 3. Remove the B+ terminal nut and wire. 4. Loosen top mounting ear bolt. Generator 5. Loosen pivot bolt, but do not remove. Be careful not to lose nut. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5239 6. Loosen adjusting bolt on idler to allow removal of the generator drive belt. 7. Remove pivot bolt, do not drop spacer. 8. Remove top mounting ear bolt. 9. Remove upper generator bracket. 10. Remove generator. INSTALLATION 1. For installation, reverse above procedures. Tighten all fasteners to the proper torque. Refer to the Torque Specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage and battery temperature. It then compensates and regulates generator current output accordingly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5253 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5254 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5255 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5256 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5257 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5258 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5259 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5260 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5261 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5262 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5263 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Recalls for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5264 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect Technical Service Bulletin # C45 Date: 040601 Recall - A/T Shifter Ignition/Park Interlock Defect June 2004 Dealer Service Instructions for: Safety Recall C45 Floor Shifter Ignition/Park Interlock IMPORTANT: Effective immediately, this recall (C45) cancels and supersedes Safety Recall No. 789 - Floor Shifter and Ignition/Part Interlock Cable. All vehicles involved in Recall 789, whether completed or not, must have Recall C45 performed. Models 1993-1999 (LH) Chrysler Concorde, LHS and 300M; Dodge Intrepid and Eagle Vision 1995-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze 1996-1999 (JX) Chrysler Sebring Convertible NOTE: This recall applies only to the above vehicles equipped with an automatic transaxle and a floor mounted shifter. 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. Involved vehicles can be determined by using the VIP inquiry process. Subject The transaxle floor shifter ignition/park interlock system on about 2,300,000 of the above vehicles may become inoperative. This may allow the shifter to be moved out of the "Park" position with the ignition key removed (or in the "Lock" position). It may also allow the ignition key to be removed when the shifter has not been placed in the "Park" position. If the shifter is not in the "Park" position, these conditions could allow the vehicle to roll away and cause a crash without prior warning. Repair The shift interlock system must be inspected for proper operation. Vehicles with a functional interlock system will have a load limiting shift lever push rod installed into the original shifter assembly. Vehicles with an inoperative interlock system must have the floor shifter assembly replaced. IMPORTANT: This recall will be implemented in six (6) phases. Parts will not be available before the applicable phase begins. Alternate Transportation If inspection determines that shifter assembly 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. IMPORTANT: This recall will be implemented in six (6) phases. Involved dealers will receive enough phase one (1) Load Limiting Push Rod Packages to service 10% of applicable vehicles. Additional Push Rod packages and shifters for implemented phases may be ordered as needed to support customer demand. The appropriate load limiting push rod part number for each vehicle is displayed on the DealerCONNECT VIP function. MOST OF THE VEHICLES INVOLVED IN THIS RECALL WILL ONLY REQUIRE A LOAD LIMITING PUSH ROD. Involved dealers will receive an initial quantity of remaining load limiting push rod packages before owner notification for those phases begin. PARTS WILL NOT BE AVAILABLE BEFORE THE APPLICABLE PHASE BEGINS. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5270 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5271 B. Floor Shifter Assemblies Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5272 Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling 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 letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5273 Vehicle owners will be notified in six (6) phases. Refer to the chart. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Ign./Park Shift Interlock Operation With the ignition key removed and your foot on the brake, depress the shifter button and attempt to move the shift lever out of the "Park" position. IMPORTANT: Use normal effort when attempting to move the shift lever. Use of excessive force may cause the floor shifter assembly to break. > If the shift lever CANNOT be moved out of the "Park" position, continue with Section "B" - Install Load Limiting Push Rod. > If the shift lever CAN be moved out of the "Park" position, the shifter assembly must be replaced. Continue with Section "C" - Floor Shifter Replacement. B. Install Load Limiting Push Rod NOTE: Only those vehicles with a properly functioning ignition/park interlock, as determined by the inspection in Section "A" require the load limiting push rod. 1. Secure the vehicle to prevent it from rolling during this service procedure. 2. Insert the key into the ignition and turn it to the "RUN" position. 3. Place shift lever into the full rearward position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5274 4. Using an allen wrench, loosen the shift handle set screw (Figure 2). 5. Remove the shift handle from the shift lever. 6. Attempt to remove the plastic push rod from the shift lever by gently pulling upward on the push rod by hand: > If the push rod can be removed, remove the push rod and continue with Step 12 of this procedure. > If the push rod cannot be removed, continue with Step 7 of this procedure 7. Using a trim stick, remove the center console shift bezel and boot. NOTE: Some vehicles may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. Locate the shift lever push rod retaining dimple (Figure 3). Most vehicles will have the dimple on the front side of the shift lever. NOTE: Some vehicles will have the dimple on the back side of the shift lever. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5275 9. Drill out the dimple using a 1/4" (6.5 mm) diameter drill bit (Figure 3). CAUTION: Care must be taken not to drill through or into the plastic push rod. NOTE: Place a shop towel around the shift lever to catch any metal chips created while drilling out the shift lever dimple. 10. Clamp locking pliers onto the end of the push rod. (Figure 4). 11. Use the following procedure to cut a groove into the plastic push rod which will create a channel that will release the push rod from the shifter. a. Insert the drill bit into the hole made in Step 9 until it lightly rests against the plastic push rod (Figure 4). b. While operating the drill, gently pull up on the locking pliers (Figure 4) that were installed in Step 10. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5276 12. If the push rod preload spring does not come out with the push rod, use the original push rod as a tool to remove the preload spring from shift lever. CAUTION: The original push rod preload spring must be removed from the shift handle before continuing with this procedure. 13. Discard the old push rod and preload spring. 14. For vehicles that had the dimple drilled out, use a small round file to remove any remaining metal burrs from the inside of the shift lever at the hole drilled in Step 9 (Figure 5). CAUTION: Failure to remove all metal burrs from inside the shift lever may make installation of the new push rod extremely difficult. 15. Orient the new load limiting push rod so that the forks are parallel with the center console (Figure 6). Insert the load limiting push rod, with the preload spring in position, into the shift lever. Be sure that the push rod is fully seated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5277 16. Install the shift bezel and boot. 17. If required, install the radio bezel. 18. Install the shift handle and tighten the set screw. 19. Check for proper shifter and ignition/park interlock operation. C. Floor Shifter Replacement NOTE: Only those vehicles with an inoperative ignition/park interlock, as determined by the inspection in Section "A," require shifter replacement. New shifter assemblies already contain the load limiting push rod. 1. Disconnect the negative battery cable. 2. Secure the vehicle to prevent it from rolling during this service procedure. 3. Insert the key into the ignition and turn to "RUN" position. 4. Place shift lever into the full rearward position. 5. Using an allen wrench, loosen the set screw in shift handle (Figure 2). 6. Remove the shift handle from the shift lever. 7. Remove the shift bezel and/or boot (Figure 7). NOTE: Some models may require the removal of the radio bezel to gain access to the shift bezel and boot. 8. With the shifter in the "PARK" position, disconnect the gearshift cable from the cable attaching stud (pin). 9. If the gearshift cable anchor bracket is part of the shifter, remove the gear shift cable retaining clip from the shifter base slot and remove the cable (Figure 7). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5278 10. With the shifter in the "PARK" position, remove the interlock cable from the shifter. NOTE: Use care not to kink the cable or break the tab on the interlock cable conduit end fitting. 11. Remove the shifter-to-floor pan attaching nuts (Figure 7). 12. Remove the old shifter assembly from the vehicle. Discard the old shifter. 13. Install the new shifter assembly into position. CAUTION: Make sure the eyelet of the shifter cable is inside of the shifter housing. 14. Install the shifter-to-floor pan attaching nuts. Tighten the nuts to 150 in. lbs. (17 Nm). 15. Install the interlock cable to the shifter housing and connect the cable to the actuator arm. 16. Connect the shift cable to the shifter. 17. Adjust the shift cable using the following procedure: a. Loosen the gearshift cable adjuster nut at the shifter assembly (Figure 8). b. Move the gearshift lever located on the transaxle to the "Park" position. CAUTION: The transaxle park sprag must be engaged when adjusting the shift cable. Rock the vehicle to verify that the sprag is engaged. c. Place the shift lever in the "Park" position. d. Verify that the shift lever and transaxle are both in the "Park" position. e. Tighten the adjuster nut to 225 in. lbs. (25 N.m) (Figure 8). f. Check adjustment as follows: > Detent position for neutral and drive should be within limits of the shift lever gate stops. > Key start must occur only when the shift lever is in the park or neutral positions. 18. Adjust the ignition/park interlock cable using the following procedure: a. Place the shift lever in the "Park" position. b. Remove the ignition key from the column lock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5279 c. Vehicles with a self adjust cable: 1. Spread the lock clip legs while pulling the lock clip upward to unlock the self-adjuster lock (Figure 9). 2. Once the lock clip is lifted, the cable will automatically adjust. 3. Push the lock clip down to lock the cable into place. d. Vehicles with a manual adjust cable: 1. Loosen the adjustment nut located on the shifter housing (Figure 10). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5280 2. Allow the cable to adjust itself to the correct position. 3. Tighten the adjustment nut to 53 in. lbs (6 N.m). e. Verify the interlock cable adjustment: > With the ignition key in the "LOCK" position, the shift lever should be locked in the "PARK" position. > Place the ignition switch in the "RUN" position. Move the shift lever to the reverse position. You should not be able to remove the ignition key from the lock cylinder. > Place the shift lever in the "PARK" position. Turn the ignition key to the "LOCK" position. You should be able to remove the ignition key from the lock cylinder. 19. Install the shift bezel and boot. 20. If required, install the radio bezel. 21. Install the shift handle and tighten the set screw. 22. Connect the negative battery cable. 23. Check for proper shifter and ignition/park interlock operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 5281 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5282 Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: - Accessory - Off (lock) - Unlock - On/Run - Start Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5283 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start Lock Cylinder Retaining Tab REMOVAL 1. Disconnect negative cable from auxillary jumper terminal -- on driver's side strut tower. 3. Remove upper steering column shroud. 3. Pull lower shroud down far enough to access lock cylinder retaining tab. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to RUN position (retaining tab on lock cylinder can be depressed). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5284 Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the RUN position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the OFF position. Remove the key. 5. Install steering column shrouds. 5. Connect negative cable to auxillary battery terminal on shock tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair Starter Motor: Service and Repair REMOVAL Remove Remote Battery Cable At Shock Tower 1. Disconnect battery negative cable from remote negative terminal on shock tower. 2. Raise vehicle. 3. Remove oil filter. Wire Terminal Connection 4. Remove battery positive cable nut from starter and remove cable. 5. Disconnect push on solenoid connector. 6. Remove three bolts attaching starter to transmission housing and remove starter from vehicle. INSTALLATION - For installation, reverse the above procedures. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center The relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for relay location. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5291 Starter Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5292 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5293 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5294 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5295 Starter Relay: Testing and Inspection Starter Relay WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED. Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Remove the starter relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery B+ lead to terminals 86 and a ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to Relay Circuit Test procedure. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between the cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the open circuit to the starter solenoid as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is energized when the ignition switch is held in the Start position. On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5. If not OK with an automatic transmission, check for an open or short circuit to the ignition switch and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position Switch Test procedure. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an automatic transmission, it is grounded through the park/neutral position switch only when the gearshift selector lever is in the Park or Neutral positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK, see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair the circuit to ground as required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection Starter Solenoid: Testing and Inspection WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APPLIED. 1. Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests. 2. Perform Starter Solenoid test before performing the starter relay test. 3. Raise the vehicle. 4. Perform a visual inspection of the starter/ starter solenoid for corrosion, loose connections or faulty wiring. 5. Lower the vehicle. 6. Locate and remove the starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. 7. Connect a remote starter switch or a jumper wire between the remote battery positive post and terminal 87 of the starter relay connector. a. If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test. b. If engine does not or solenoid chatters, check wiring and connectors from starter relay to starter solenoid for loose or corroded connections. Particularly at starter terminals. c. Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted solenoid, and replace starter. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Auxiliary Power Outlet: Electrical Diagrams Horn/Cigar Lighter/Power Outlet NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5321 Auxiliary Power Outlet: Description and Operation CIRCUIT OPERATION The power outlet is powered by a 40 amp fuse located in the Power Distribution Center (PDC). There is also a 20 amp fuse located in cavity 8 of the junction block. Ground for the lighter is provided on the Z1 circuit and terminates at the instrument left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5322 Auxiliary Power Outlet: Testing and Inspection - Check the 40 amp fuse located in cavity 12 of the PDC - Check the 20 amp fuse located in cavity 8 of the junction block - Check for a good ground at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5323 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Remove cubby bin. 2. Disconnect the two power outlet wiring connectors from power outlet. Unscrew shell and clamp assembly to replace power outlet. INSTALLATION - For installation, reverse the above procedures. The clamp has a locating feature. The cubby bin must engage the console at its forward edge prior to installing the mounting screws. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 Power Distribution Center: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 Power Distribution Center: Connector Views Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution (Part 1 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 Power Distribution (Part 2 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 Power Distribution (Part 3 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 Power Distribution (Part 4 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 Power Distribution (Part 5 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 Power Distribution (Part 6 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 Power Distribution (Part 7 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 Power Distribution (Part 8 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 Power Distribution (Part 9 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 Power Distribution (Part 10 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 Power Distribution (Part 11 Of 11) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Ground Distribution Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 Ground Distribution (Part 1 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 Ground Distribution (Part 2 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 Ground Distribution (Part 3 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 Ground Distribution (Part 4 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 Ground Distribution (Part 5 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Ground Distribution (Part 6 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 Ground Distribution (Part 7 Of 7) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5371 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5372 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations Multiple Junction Connector: Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Multiple Junction Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Multiple Junction Connector: Connector Views Junction Block Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Junction Block Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 Junction Block Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 Junction Block NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 Multiple Junction Connector: Electrical Diagrams Junction Block (Part 1 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 Junction Block (Part 2 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 Junction Block (Part 3 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 Junction Block (Part 4 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5402 Junction Block (Part 5 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5403 Junction Block (Part 6 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 Junction Block (Part 7 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 Junction Block (Part 8 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 Junction Block (Part 9 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 Junction Block (Part 10 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Junction Block (Part 11 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Junction Block (Part 12 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Junction Block (Part 13 Of 13) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Auxiliary Power Outlet: Electrical Diagrams Horn/Cigar Lighter/Power Outlet NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5440 Auxiliary Power Outlet: Description and Operation CIRCUIT OPERATION The power outlet is powered by a 40 amp fuse located in the Power Distribution Center (PDC). There is also a 20 amp fuse located in cavity 8 of the junction block. Ground for the lighter is provided on the Z1 circuit and terminates at the instrument left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5441 Auxiliary Power Outlet: Testing and Inspection - Check the 40 amp fuse located in cavity 12 of the PDC - Check the 20 amp fuse located in cavity 8 of the junction block - Check for a good ground at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5442 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Remove cubby bin. 2. Disconnect the two power outlet wiring connectors from power outlet. Unscrew shell and clamp assembly to replace power outlet. INSTALLATION - For installation, reverse the above procedures. The clamp has a locating feature. The cubby bin must engage the console at its forward edge prior to installing the mounting screws. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 Power Distribution Center: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Power Distribution Center: Connector Views Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution (Part 1 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Power Distribution (Part 2 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Power Distribution (Part 3 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 Power Distribution (Part 4 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Power Distribution (Part 5 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Power Distribution (Part 6 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Power Distribution (Part 7 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Power Distribution (Part 8 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 Power Distribution (Part 9 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Power Distribution (Part 10 Of 11) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 Power Distribution (Part 11 Of 11) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Ground Distribution Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Ground Distribution (Part 1 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Ground Distribution (Part 2 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 Ground Distribution (Part 3 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 Ground Distribution (Part 4 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Ground Distribution (Part 5 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Ground Distribution (Part 6 Of 7) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 Ground Distribution (Part 7 Of 7) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5490 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 5491 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations Multiple Junction Connector: Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Multiple Junction Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Multiple Junction Connector: Connector Views Junction Block Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Junction Block Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 Junction Block Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 Junction Block NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 Multiple Junction Connector: Electrical Diagrams Junction Block (Part 1 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 Junction Block (Part 2 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Junction Block (Part 3 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 Junction Block (Part 4 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 Junction Block (Part 5 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 Junction Block (Part 6 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 Junction Block (Part 7 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 Junction Block (Part 8 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 Junction Block (Part 9 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 Junction Block (Part 10 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 Junction Block (Part 11 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 Junction Block (Part 12 Of 13) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 Junction Block (Part 13 Of 13) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications FRONT WHEEL ALIGNMENT: Camber: Acceptable Range ................................................................................................................ ...................................................................... -0.6 to to +0.6° Preferred Setting .................................. .............................................................................................................................................................. .......... 0.0° Toe Right/Left: Acceptable Range ....................................................................................................... ................................................................... +0.05° out to +0.15° in Preferred Setting ........................ .............................................................................................................................................................. ............ +0.05° in Total Toe: [1] Acceptable Range ......................................................................................................... ..................................................................... +0.1° out to +0.3° in Preferred Setting .......................... .............................................................................................................................................................. ............ +0.1° in Caster:* Acceptable Range ................................................................................................................. ........................................................................ +2.3 to +4.3° Preferred Setting ................................... .............................................................................................................................................................. ....... +3.3° *Side To Side Caster Difference Not To Exceed: Acceptable Range ................................................. ......................................................................................................................................... +1.0° or less Preferred Setting .......................................................................................................................... ................................................................................ 0.0° REAR WHEEL ALIGNMENT: Camber: Acceptable Range ................................................................................................................ ...................................................................... -0.6 to to +0.2° Preferred Setting .................................. .............................................................................................................................................................. ......... -0.2° Toe Right/Left: Acceptable Range ....................................................................................................... ................................................................... +0.05° out to +0.15° in Preferred Setting ........................ .............................................................................................................................................................. ............ +0.05° in Total Toe: [2] Acceptable Range ......................................................................................................... ..................................................................... +0.1° out to +0.3° in Preferred Setting .......................... .............................................................................................................................................................. ............ +0.1° in Thrust Angle: Acceptable Range ......................................................................................................... ......................................................................... -0.15 to to +0.15° Preferred Setting ........................... .............................................................................................................................................................. ................. 0.0° [1] Total toe is the arithmetic sum of the left and right wheel toe settings. Positive is Toe-in, negative is Toe-out. Total Toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Left and right toe must be equal to within 0.02 degrees. [2] Toe Out: When backed on Alignment Rack is Toe In when driving. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Information Alignment: Description and Operation General Information Proper vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspension angles. These angles are what affects the handling and steering of the vehicle when it is in motion. The method of checking a vehicle's front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used. Instructions furnished by the manufacturer of the equipment being used should always be followed to ensure accuracy of the alignment, except alignment specifications recommended by Chrysler Corporation MUST ALWAYS be used. CAUTION: Do not attempt to modify any suspension or steering components by heating or bending of the component. Wheel alignment adjustments should always be made in the following sequence, to ensure that an accurate alignment is performed. 1. Adjust rear camber to be at the preferred setting specification. 2. Adjust rear wheel Toe to be at the preferred setting specification.. 3. Adjust front wheel Toe to be at the preferred setting specification for individual wheel Toe and for total Toe. 4. Toe is measured in degrees or inches and is the distance that the front edges of the tires are closer (or farther apart) than the rear edges. 5. Thrust Angle is defined as the average of the Toe settings on each rear wheel. If this measurement is out of specification, re-adjust rear wheel Toe so that each wheel has 1/2 of the total Toe measurement. When re-adjusting, do not exceed the total Toe specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Information > Page 5543 Alignment: Description and Operation Caster/Camber Description On this vehicle, the front suspension caster and camber settings and the rear suspension caster settings, are determined at the time the vehicle is designed. This is accomplished by very accurately locating the vehicle's suspension components when designing and assembling the vehicle. This is called a Net Build: vehicle and results in no required or available adjustment of front and rear caster and front camber after the vehicle is built or when servicing the suspension components. Thus Caster and Camber are not normally considered an adjustable specification when performing an alignment on this vehicle. Though Caster and Camber are not adjustable they must be checked to ensure they meet vehicle specifications. If a vehicle's front camber is found to be outside of the required specifications, the vehicles front suspension components should be inspected for any signs of damage or bending. Rear Camber on this vehicle is adjustable. The rear camber on this vehicle is adjusted using the adjusting screw located in the forward and rear lateral links of the vehicles rear suspension. Rear Caster on this vehicle is not adjustable and is not shown as an alignment specification. CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating, bending or any other modification of the suspension components. NOTE: When checking the rear alignment on this vehicle the alignment rack must be equipped with rear skid plates. Correctly position vehicle on alignment rack and install all required equipment on vehicle, per the alignment equipment manufacturers specifications. NOTE: Prior to reading each alignment specification, front and rear of vehicle should be jounced an equal number of times. Induce jounce-(rear first then front) by grasping center of bumper and jouncing each end of vehicle an equal number of times. Bumper should always be released when vehicle is at the bottom of the jounce cycle. Correctly jounce vehicle and read front and rear alignment settings and compare to vehicle specifications for camber, caster and toe. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5544 Alignment: Testing and Inspection Before any attempt is made to change or correct the wheel alignment factors. The following part inspection and the necessary corrections should be made to those parts, which influence the steering of the vehicle. 1. Check and inflate all tires to recommended pressure. All tires should be the same size and in good condition and have approximately the same wear. Note the type of tread wear which will aid in diagnosing. 2. Check front wheel and tire assembly for radial runout. 3. Inspect lower ball joints and all steering linkage for looseness. 4. Check for broken or sagged front and rear springs. 5. Check vehicle ride height to verify it is within specifications. 6. Alignment MUST only be checked after the vehicle has the following areas inspected and or adjusted. Recommended tire pressures, full tank of fuel, no passenger or luggage compartment load and is on a level floor or a properly calibrated alignment rack. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5545 Alignment: Service and Repair FRONT WHEEL TOE AND REAR WHEEL TOE AND CAMBER SETTING PROCEDURE 1. Prepare vehicle as described in the-Pre-Alignment Vehicle Inspection procedure. 2. Center steering wheel and lock in place using a steering wheel clamp. NOTE: When performing the Front Toe and Rear Camber and Toe setting procedure, the rear wheel Camber and Toe MUST be set to the preferred specification first, then set front wheel Toe to the preferred specification. CAUTION: Do not attempt to straighten or repair a lateral link. Do not apply heat to the lateral link adjusting screws or to the jam nuts, when loosening or adjusting the lateral links. 3. Loosen the adjusting screw jam nuts on all 4 of the rear lateral arm adjusting screws. CAUTIONS: Do not attempt to move the adjusting screws without properly loosening the jam nuts. Note that each adjusting screw has one right-handed nut and one left-handed nut. - When setting rear Camber and Toe on the vehicle, the maximum lengths of the adjustable lateral link at the locations shown must not be exceeded. If these maximum lengths are exceeded, inadequate retention of adjustment link to the inner and outer link may result. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5546 4. Rough in Rear Camber setting as close as possible to the preferred specification first, by mainly adjusting the rear lateral link adjusting screw. Some adjustment of the forward lateral link adjusting screw will also be required to get Rear Camber setting to preferred specification. 5. Adjust the forward lateral link adjusting screw to set rear Toe to preferred specification. - Adjusting Toe will cause a slight change in the Camber setting. If during setting of Toe, Camber no longer is at the preferred specification, continue to adjust Camber and Toe until both are at their preferred specifications. 6. While holding adjustment screws from turning, use a crow foot and torque wrench, and tighten all lateral link adjusting screw jam nuts to a torque of 65 Nm (48 ft. lbs.). This will securely hold adjusting screws from turning. CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. 7. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate inner tie rods of steering gear to set front Toe to the preferred Toe specification. 8. Tighten tie rod locknuts to 61 Nm (45 ft. lbs.) torque. 9. Adjust steering gear to tie rod boots at inner tie rod. 10. Remove steering wheel clamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 5552 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revision NUMBER: 26-10-96 GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus, Stratus & Breeze - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs 8W-80-44 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 5559 8W-80-45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 5560 8W-80-46 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 5561 8W-80-47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 5564 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5565 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5566 Power Steering Pressure Switch: Description and Operation Fig. 21 Power Steering Pressure Switch PURPOSE On some vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. OPERATION The pressure switch improves vehicle idle quality, by maintaining required engine idle speed when necessary, do to increased pressure in the power steering system. This increased pressure will slow down the power steering pump which will decrease engine idle speed. The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear on vehicle's requiring its usage. When power steering pump pressure exceeds 4137 kPa (600 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z1 provides a ground for the power steering pressure switch. The ground is terminated at the left strut tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5567 Power Steering Pressure Switch: Service and Repair REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on the back side of the power steering gear. 4. Remove the vehicle's wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service Precautions Front Steering Knuckle: Service Precautions CAUTION: The front suspension steering knuckle is not a repairable component of the front suspension. IT MUST BE REPLACED IF FOUND TO BE DAMAGED IN ANY WAY. If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the steering knuckle. NOTE: On this vehicle the steering knuckle must be removed from the vehicle when servicing the front hub bearing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service Precautions > Page 5572 Front Steering Knuckle: Description and Operation The steering knuckle is a single casting with legs machined for attachment to the vehicle's upper and lower control arm ball joints. The steering knuckle also has machined abutments on the casting to support and align the front brake caliper assembly. The knuckle also holds the front drive shaft outer C/V joint hub and bearing assembly. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. The outer C/V joint is retained to the hub and bearing assembly using a nut, nut lock and cotter pin. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal 1. Remove cotter pin, nut lock, and spring washer from the front stub axle. CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 2. Loosen hub nut while 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 on jack stands or centered on a frame contact type hoist. 4. Remove front tire and wheel assembly from the hub. 5. Remove front disc brake caliper to steering knuckle guide pin attaching bolts. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5575 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. 7. Support brake caliper/adapter assembly using a wire hook and not by hydraulic hose. 8. Remove the braking disc from the front hub/bearing assembly. 9. If vehicle is equipped with 15 inch wheels, remove lower ball joint heat shield from lower control arm. Heat shield must be removed before attempting to separating ball joint stud from steering knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5576 10. Remove nut attaching outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. 11. Remove the tie rod end from steering knuckle arm, using Remover, Special Tool MB-991113, or equivalent. 12. If equipped with antilock brakes remove the speed sensor cable routing bracket from the steering knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5577 13. Remove cotter pin and castle nut from stud of lower ball joint at the steering knuckle. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in step Step 14 below. 14. Turn steering knuckle so the front of the steering knuckle is facing as far outboard-in the wheel well as possible. Using a hammer strike the boss on the steering knuckle, until steering knuckle separates from stud of lower ball joint. When striking steering knuckle care MUST be taken not to hit lower control arm or ball joint grease seal. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. Refer to Transmission and Drivetrain. 15. Lift up on steering knuckle separating it from the lower ball joint stud. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5578 16. Separate the steering knuckle from the outer C/V joint. Separate steering knuckle from outer C/V joint, by supporting the driveshaft while pulling steering knuckle away from the outer C/V joint. 17. Remove the cotter pin and nut from the upper ball joint stud to steering knuckle attachment. 18. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C-3894-A, or equivalent. 19. Remove steering knuckle from vehicle. 20. The bolt in type front wheel bearing used on the vehicle is transferable to the replacement steering knuckle if bearing is found to be in usable condition. Refer to Transmission and Drivetrain for proper wheel bearing removal and installation procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5579 Front Steering Knuckle: Service and Repair Installation 1. If required install a hub/bearing assembly into the steering knuckle before installing steering knuckle on vehicle. Refer to Transmission and Drivetrain for proper wheel bearing removal and installation procedure. 2. Slide drive shaft back into front hub/bearing assembly. Then install steering knuckle onto the ball joint stud in lower control arm. 3. Install the steering knuckle to lower ball joint stud castle nut. 4. Install upper ball joint in steering knuckle. Install the steering knuckle to upper ball joint nut. Tighten the upper ball joint castle nut to a torque of 62 Nm (45 ft. lbs.). Then, using a crowfoot and torque wrench, tighten the lower ball joint nut to a torque of 75 Nm (55 ft. lbs.). Install cotter pins in upper and lower ball joint studs. 5. If equipped with antilock brakes install the speed sensor cable routing bracket on the steering knuckle and securely tighten the attaching bolt. CAUTION: When installing tie rod on steering knuckle the heat shield must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5580 6. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). CAUTION: The ball joint seal boot heat shield must be installed. If heat shield is not installed, ball joint seal boot can fail due to excessive heat from brake rotor. 7. Install the lower ball joint heat shield on the steering knuckle. 8. Install braking disc back on hub and bearing assembly. 9. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 10. Install disc brake caliper assembly to steering knuckle guide pin bolts. Tighten caliper assembly guide pin bolts to a torque of 31 Nm (23 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5581 11. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install washer and hub nut onto stub axle and tighten nut. 12. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 203 Nm (150 ft. lbs.) of torque. 13. Install the spring washer, hub nut lock, and new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock. 14. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Then tighten to a torque of 129 Nm (95 ft. lbs.). 15. Lower vehicle. 16. Set front Toe on vehicle to required Alignment specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 5591 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5597 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5598 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5599 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 5604 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5610 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5611 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5612 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5613 Power Steering Fluid: Specifications The OE Service Manual does not provide a Power Steering Fluid Type Specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5614 Power Steering Fluid: Service and Repair WARNING: Fluid level should be checked with engine off to prevent injury from moving parts. Do not use automatic transmission fluid in the power steering system. Do not overfill the power steering system. Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approximately 21°C - 27°C (70°F - 80°F). In all pumps add fluid as necessary, use only Mopar Power Steering Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair REMOVE 1. Raise vehicle using a frame contact type hoist or supported as required using jack stands. 2. Remove the front fascia and the grill as an assembly from the vehicle. 3. Remove the hose clamps from the power steering fluid hoses. Drain power steering fluid from the hoses and the power steering fluid cooler. 4. Remove bolt attaching the power steering fluid cooler to the bumper reinforcement. INSTALL 1. Install the power steering fluid cooler on the bumper reinforcement as shown. 2. Install bolt attaching the power steering fluid cooler to the bumper reinforcement. Tighten the attaching bolt to a torque of 7 Nm (60 inch lbs.). 3. Install power steering fluid hoses on the power steering fluid cooler. Install the hose clamps on the power steering fluid hoses. Be sure hose clamps are installed on hose past the upset bead on the power steering oil cooler. 4. Install the front fascia and grill on the vehicle. 5. Lower the vehicle to a point where front tires are just off the ground. 6. Start the engine and let run for a few seconds. Then turn the engine off. 7. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 8. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 9. Add power steering fluid if necessary. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications Power Steering Fluid Reservoir: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 28 Nm (21 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 5621 Power Steering Fluid Reservoir: Service and Repair REMOVE 1. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 2. Raise vehicle. 3. Remove hose clamp attaching power steering fluid supply hose to fitting on power steering pump. Let power steering fluid drain from supply hose and power steering fluid reservoir, until reservoir is empty. 4. Lower vehicle. CAUTION: Care must be used when removing and installing power steering fluid hoses on the power steering fluid reservoir. If excessive force is used when trying to remove or install hoses on nipples of power steering fluid reservoir, nipples can be broken off the reservoir. 5. Remove power steering fluid return and supply hose, from power steering fluid reservoir. 6. Remove bolts attaching power steering fluid reservoir to engine. 7. Remove power steering fluid reservoir from vehicle. INSTALL 1. Install power steering fluid reservoir on cylinder head. Install and securely tighten the power steering fluid reservoir attaching bolts. 2. Install-power steering fluid return and supply hose, on power steering fluid reservoir fittings. Be sure both hose clamps are installed on hose past upset bead on power steering reservoir fittings. 3. Raise vehicle. 4. Install power steering supply hose, on suction fitting of the power steering pump. Be sure hose clamp is installed on hose past upset bead on power steering gear steel tube. 5. Fill power steering pump fluid reservoir to the proper level. 6. Start the engine and let run for a few seconds. Then turn the engine off. 7. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 8. Raise front wheels of vehicle off the ground. 9. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 10. Add power steering fluid if necessary. 11. Lower the vehicle and turn the steering wheel slowly from lock to lock. 12. Stop the engine. Check the fluid level and refill as required. 13. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-06-96 > Dec > 96 > Power Steering Pump - Moaning Noise Power Steering Line/Hose: Customer Interest Power Steering Pump - Moaning Noise NO: 19-06-96 GROUP: Steering DATE: Dec. 6, 1996 SUBJECT: Power Steering Pump Noise MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Moaning noise from power steering pump. Noise will increase with steering input and temperature. DIAGNOSIS: Check power steering fluid level, adjust as required. Listen for power steering pump moaning noise. If noise increases with steering input and temperature perform Repair Procedure. PARTS REQUIRED: AR(1) 04764347AA Hose, Power Steering Pressure, 2.0L/2.4L Engine AR(1) 04764349AA Hose, Power Steering Pressure, 2.5L Engine REPAIR PROCEDURE: This bulletin involves replacing the power steering pressure hose with a revised part. 1. Install the revised power steering pressure hose as described on page 19-14 of the 1997 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-7121). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-10-93 2.8 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-06-96 > Dec > 96 > Power Steering Pump - Moaning Noise Power Steering Line/Hose: All Technical Service Bulletins Power Steering Pump - Moaning Noise NO: 19-06-96 GROUP: Steering DATE: Dec. 6, 1996 SUBJECT: Power Steering Pump Noise MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Moaning noise from power steering pump. Noise will increase with steering input and temperature. DIAGNOSIS: Check power steering fluid level, adjust as required. Listen for power steering pump moaning noise. If noise increases with steering input and temperature perform Repair Procedure. PARTS REQUIRED: AR(1) 04764347AA Hose, Power Steering Pressure, 2.0L/2.4L Engine AR(1) 04764349AA Hose, Power Steering Pressure, 2.5L Engine REPAIR PROCEDURE: This bulletin involves replacing the power steering pressure hose with a revised part. 1. Install the revised power steering pressure hose as described on page 19-14 of the 1997 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-7121). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-10-93 2.8 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 5635 Power Steering Line/Hose: Specifications Hose Tube Nuts ................................................................................................................................... ..................................................... 54 Nm (40 ft. lbs.) Return Hose Bracket To Head ......................... ......................................................................................................................................... 28 Nm (21 ft. lbs.) Pressure Hose to Return Hose Bracket .................................................................................................................................................... 9 Nm (75 inch lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 5636 Power Steering Line/Hose: Testing and Inspection SYMPTOM/CONDITION Moaning noise from power steering pump. Noise will increase with steering input and temperature. DIAGNOSIS Check power steering fluid level, adjust as required. Listen for power steering pump moaning noise. If noise increases with steering input and temperature, refer to TSB # 19-06-96, dated 12/06/96 for a possible repair procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump REMOVE 1. Using a siphon pump, remove as much power steering fluid as possible from the remote power steering fluid reservoir. CAUTION: Care must be used when removing the power steering fluid supply hose from power steering fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steering fluid reservoir, nipple can break off of the reservoir. Fig. 8 2. Remove hose clamp, attaching power steering fluid supply hose to the power steering fluid reservoir. Then remove power steering fluid supply hose from power steering fluid reservoir. 3. Raise vehicle. 4. Remove hose clamp, attaching power steering fluid supply hose to the power steering pump. Then remove power steering fluid supply hose from power steering pump fitting. INSTALL 1. Install power steering fluid supply hose on power steering pump fitting, making sure it is correctly routed up to the power steering fluid reservoir. Install hose clamp on power steering fluid supply hose at power steering pump fitting. Be sure hose clamp is installed on power steering fluid supply hose past upset bead on power steering pump fitting. 2. Lower vehicle. CAUTION: Care must be used when installing power steering fluid supply hose on power steering fluid reservoir. If excessive force is used when trying to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir. 3. Install power steering fluid supply hose on power steering fluid reservoir fitting. Install hose clamp on power steering fluid supply hose at power Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5639 steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 4. Fill power steering fluid reservoir. 5. Start the engine and let run for a few seconds. Then turn the engine off. 6. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 7. Raise front wheels of vehicle off the ground. 8. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 9. Add power steering fluid if necessary. 10. Lower the vehicle and turn the steering wheel slowly from lock to lock. 11. Stop the engine. Check the fluid level and refill as required. 12. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 13. After hose is installed, check for leaks at all hose connections. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5640 Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. NOTES: - To service the power steering pressure hose on this vehicle, the front suspension crossmember and steering gear will need to be lowered away from the body and frame of the vehicle. This is required for access to the power steering hose connections on the side of the steering gear. - Service all power steering hoses with the vehicle raised on a hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent the entry of foreign material into the components. REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. CAUTION: When lowering the front suspension crossmember, its installed position on the vehicle's body must be marked on the crossmember before it is lowered. 2. Lower the front suspension crossmember far enough to gain access to the high and low pressure ports on the steering gear. 3. Disconnect the power steering pressure hose at the power steering gear. Drain power steering fluid from power steering pump and hose through open end of hose. 4. Remove the 2 routing brackets attaching the power steering return hose to the power steering pressure hose routing brackets. Then remove the 2 bolts attaching the power steering pressure hose routing brackets to the cylinder head. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5641 5. Remove the tie-strap holding the power steering fluid supply hose to the power steering pressure hose. 6. Remove the power steering pressure hose from the pressure fitting on power steering pump. 7. Power steering fluid pressure hose is removed from the vehicle from the bottom rear of engine compartment. 8. Discard all used O-rings located at ends of power steering pressure hose fittings. INSTALL 1. Install power steering pressure hose in vehicle from bottom of engine compartment using the reverse order of removal. 2. Using a lint free towel, wipe clean all open power steering hose ends, and the power steering pump and steering gear ports. 3. Install new O-rings on the power steering pressure hose fittings. 4. Lubricate both O-rings using fresh clean power steering fluid. 5. Attach power steering pressure hose to outlet; fitting on power steering pump. Do not tighten or torque pressure fitting at this time. CAUTION: Hoses must remain away from exhaust system, vehicle components and unfriendly surfaces causing possible damage to power steering hoses. 6. Correctly route power steering pressure hose avoiding tight bends or kinking of the hose. Install power steering pressure hose routing brackets and attaching bolts on engine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5642 7. Route power steering pressure hose to pressure port on power steering gear. Install power steering pressure hose, on steering gear and loosely install tube nut into steering gear. Then using a crow foot, tighten the power steering pressure hose tube nut to a torque of 31 Nm (275 inch lbs.). CAUTION: When installing the front suspension crossmember, it must be installed back in the same location on the vehicle's body as when it was originally installed when the vehicle was built. 8. Raise the front suspension crossmember and steering gear back up into the vehicle. Refer to the steering gear service procedure in this group of the service manual for the required procedure to install the front suspension crossmember. CAUTION: The tie strap must be installed on the power steering pressure hose and supply hose to ensure proper routing of the hoses. 9. Install the tie-strap holding the power steering fluid supply hose to the power steering pressure hose. 10. Lower vehicle. 11. Start the engine and let run for a few seconds. Then turn the engine off. 12. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 13. Raise front wheels of vehicle off the ground. 14. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 15. Add power steering fluid if necessary. 16. Lower the vehicle and turn the steering wheel slowly from lock to lock. 17. Stop the engine. Check the fluid level and refill as required. 18. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 19. After hose is installed, check for leaks at all hose connections. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5643 Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose Removal WARNING: Power steering oil, engine parts and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. NOTES: - To remove the power steering return hose on this vehicle, the front suspension crossmember and steering gear will need to be lowered away from the body of the vehicle. This is required for access to the power steering hose connections on the side of the steering gear. Refer to the steering gear service procedure in this group of the service manual for the required procedure to remove the front suspension crossmember. - Service all power steering hoses with the vehicle raised on a hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent the entry of foreign material into the components. 1. Siphon all power steering fluid from the power steering fluid reservoir. CAUTION: Care must be used when removing power steering fluid return hose from power steering fluid reservoir. If excessive force is used when trying to remove hose from nipple on power steering fluid reservoir, nipple can break off of the reservoir. 2. Remove power steering fluid return hose from nipple on power steering fluid reservoir. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. CAUTION: When lowering the front suspension crossmember, its installed position on the vehicle's body must be marked on the crossmember before it is lowered. 4. Lower the front suspension crossmember far enough to gain access to the high and low pressure ports on the steering gear. 5. Disconnect power steering fluid return hose at power steering gear. Drain power steering fluid from hose. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5644 6. Remove the 2 routing brackets attaching the power steering return hose to the power steering pressure hose routing brackets. 7. Remove the power steering return hose from the vehicle. The power steering return hose is removed from the bottom of the engine compartment. Installation 1. Install power steering return hose on vehicle. Power steering return hose is installed from the bottom of the vehicles engine compartment using the reverse steps of removal. 2. Using a lint free towel, wipe clean all open power steering hose ends, and the power steering gear port. 3. Install a new O-ring on the power steering return hose to steering gear fitting. 4. Lubricate O-ring using fresh clean power steering fluid. 5. Install power steering return hose, on steering gear and loosely, install tube nut into steering gear. Then using a crow foot, tighten the power steering pressure hose tube nut to a torque of 31 Nm (275 inch lbs.). CAUTION: Hoses must remain away from exhaust system, vehicle components and unfriendly surfaces causing possible damage to power steering hoses. 6. Correctly route power steering return hose up to the power steering fluid reservoir, avoiding tight bends or kinking of the hose. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5645 7. Install the 2 routing brackets attaching the power steering return hose to the power steering pressure hose routing brackets. CAUTION: When installing the front suspension crossmember, it must be installed back in the same location on the vehicle's body as when it was originally installed when the vehicle was built. 8. Raise the front suspension crossmember and steering gear back up into the vehicle. 9. Lower vehicle. CAUTION: Care must be used when installing power steering fluid return hose on power steering fluid reservoir. If excessive force is used when trying to install hose on nipple of power steering fluid reservoir, nipple can be broken off the reservoir. 10. Install power steering return hose on power steering fluid reservoir fitting. Install hose clamp on power steering return hose at power steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. 11. Start the engine and let run for a few seconds. Then turn the engine off. 12. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 13. Raise front wheels of vehicle off the ground. 14. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 15. Add power steering fluid if necessary. 16. Lower the vehicle and turn the steering wheel slowly from lock to lock. 17. Stop the engine. Check the fluid level and refill as required. 18. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 19. After hose is installed, check for leaks at all hose connections. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5646 Power Steering Line/Hose: Service and Repair Power Steering Fluid Cooler Lines Removal 1. Remove intermediate steering shaft coupler from the steering gear shaft. 2. Siphon as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle using a frame contact type hoist or supported as required using jack stands. 4. Remove the left front wheel/tire. 5. Remove the front fascia and the grill as an assembly from the vehicle. 6. Remove the hose clamps from the power steering fluid hoses. Drain power steering fluid from the hoses and the power steering fluid cooler. 7. Remove-the-bracket attaching the power steering fluid cooler lines to the left front frame rail. 8. Lower the front suspension crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5647 9. Remove the clip holding the power steering fluid cooler lines together. 10. Remove the hose clamp attaching the power steering fluid return hose from the engine, to the power steering fluid cooler lines. 11. Remove the power steering fluid return hose from the power steering gear. 12. Remove the power steering fluid cooler lines from the routing clip on the left front frame rail. 13. Separate the power steering cooler line assembly into 2 separate pieces. 14. Remove each cooler line separately from the vehicle. The cooler lines are removed out through the front of the vehicle in the area between the radiator and the closure panel. Installation 1. Install the cooler lines individually using the reverse procedure of their removal. 2. Install the cooler lines in the routing clip on the left frame rail. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5648 3. Install the power steering fluid return hose coming from the engine on the power steering cooler line. Install the hose clamp on the power steering fluid hose. Be sure hose clamp is installed on hose past the upset bead on the power steering cooler line. 4. Install the power steering fluid return hose on the steering gear. Then using a crow foot and torque wrench tighten the tube nut to a torque of 31 Nm (275 inch lbs.). 5. Install the-clip holding the 2 power steering fluid cooler lines together. 6. Install the front suspension crossmember. 7. Install the left front wheel/tire. 8. Install the bracket attaching the power steering cooler lines to the left frame rail. Install bracket attaching bolt and tighten to a torque of 7 Nm (60 inch lbs.). 9. Install power steering fluid hoses on the power steering fluid cooler. Install the hose clamps on the power steering fluid hoses. Be sure hose clamps are installed on hose past the upset bead on the power steering oil cooler. 10. Install the front fascia and grill on the vehicle. 11. Lower the vehicle to a point where front tires are just off the ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 5649 12. Connect the steering column intermediate shaft on the shaft of the steering gear. Install the coupler retaining pinch bolt and tighten to a torque of 27 Nm (240 inch lbs.). Be sure to install the coupler retaining pinch bolt retention pin. 13. Start the engine and let run for a few seconds. Then turn the engine off. 14. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 15. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 16. Add power steering fluid if necessary. 17. Stop the engine. Check the fluid level and refill as required. 18. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Pump: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 5661 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5667 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5668 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5669 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Pump: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 5674 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 26-11-97B > Nov > 97 > Steering - Power Steering Pump R & I Revision Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Pump R & I Revision NUMBER: 26-11-97B GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus/Stratus/Breeze Service Manual - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Revisions to the power steering removal and installation procedure Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 26-11-97B > Nov > 97 > Steering - Power Steering Pump R & I Revision > Page 5679 19-25 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5685 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5686 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 5687 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 26-11-97B > Nov > 97 > Steering - Power Steering Pump R & I Revision Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Pump R & I Revision NUMBER: 26-11-97B GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus/Stratus/Breeze Service Manual - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Revisions to the power steering removal and installation procedure Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 26-11-97B > Nov > 97 > Steering - Power Steering Pump R & I Revision > Page 5692 19-25 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Discharge Fitting .................................................................................................................................. .................................................... 75 Nm (55 ft. lbs.) To Rear Bracket Mounting Bolts .............................................................................................................................................................. 54 Nm (40 ft. lbs.) To Front Bracket Mounting Bolts ............................................................................................................................................................. 54 Nm (40 ft. lbs.) Bracket to Engine Mounting Bolts ........................................................................................................................................................... 54 Nm (40 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5695 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Flow at 1500 RPM ............................................................................................................................... ................................ 4.9 - 5.3 Liters (1.3 - 1.4 GPM) Control Valve Pressure Relief ......................................................................................................................................... 8240 - 8920 kPa (1195 - 1293 psi) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5696 Power Steering Pump: Description and Operation On all vehicles equipped with power steering, the hydraulic pressure for operation of the power steering gear is provided by a belt driven power steering pump. The TTA power steering pump is a constant flow rate and displacement, vane type pump. In the event of a power steering pump drive belt failure, manual steering control of the vehicle can still be maintained. However, under these conditions, steering effort will be significantly increased. All vehicles equipped with power steering use a remote mounted reservoir for the power steering fluid. The power steering fluid remote reservoir engine is mounted to the front side of the engine between the cylinder heads. The service procedures for the TTA power steering pump are limited to the areas and components listed below. No repair procedures are to be done on internal components of the TTA power steering pumps. - Repair of power steering fluid leaks from areas of the power steering pump sealed by O-rings is allowed. However power steering pump shaft seal leakage will require replacement of the pump. - Power steering fluid reservoirs, related components and attaching hardware. - Power steering fluid reservoir filler cap/dipstick assemblies. Because of unique shaft bearings, flow control levels or pump displacements, power steering pumps may be used only on specific vehicle applications. Be sure that all power steering pumps are only replaced with a pump that is the correct replacement for that specific application. Hydraulic pressure is provided for operation of the power steering gear by the belt driven power steering pump. It is a constant displacement, vane type pump. The power steering pump is connected to the steering gear by a power steering fluid pressure hose, return hose and the remote power steering fluid reservoir. Rectangular pumping vanes in the shaft driven rotor, move power steering fluid from the intake to the cam ring pressure cavities of the power steering pump. As the rotor begins to turn, centrifugal force throws the vanes against the inside surface of the cam ring to pickup residual oil. This oil is then forced into the high pressure area. As more oil is picked up by the vanes, the additional oil is forced into the cavities of the thrust plate through two crossover holes in the cam ring and pressure plate. The crossover holes empty into the high pressure area between the pressure plate and the housing end cover. As the high pressure area is filled, oil flows under the vanes in the rotor slots, forcing the vanes to follow the inside surface of the cam ring. As the vanes reach the restricted area of the cam ring, oil is forced out from between the vanes. When excess oil flow is generated during high-speed operation, a regulated amount of oil returns to the pump intake side through a flow control valve. The flow control valve reduces the power required to drive the pump and holds down temperature build-up. When steering conditions exceed maximum pressure requirements, such as when the wheels are turned against the stops. The pressure built up in the steering gear exerts pressure on the spring end of the flow control valve. The high pressure lifts the relief valve ball from its seat and allows oil to flow through a trigger orifice located in the outlet fitting. This reduces pressure on the spring end of the flow control valve which then opens and allows the oil to return to the intake side of the pump. This action limits maximum pressure output of the pump to a safe level. Under normal power steering pump operating conditions, pressure requirements of the pump are below maximum, causing the pressure relief valve to remain closed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Seal Replacement NOTE: The power steering pump does not require removal from the engine for removal and replacement of the flow control valve fitting O-Ring. REMOVAL 1. Remove the power steering fluid pressure hose from power steering pump pressure fitting. 2. Remove the power steering pump discharge/ flow control valve fitting from the power steering pump housing. Use care to prevent the flow control valve and spring from sliding out of the discharge/flow control valve fitting. 3. Remove and discard O-ring seal from fitting. INSTALLATION 1. If necessary, clean and install flow control valve and spring in pump housing bore. 2. Install new O-ring seal on fitting. 3. Install the discharge/flow control valve fitting into the power steering pump. Tighten the discharge/flow control valve to a torque of 75 Nm (65 ft. lbs.). 4. Install power steering fluid pressure hose on flow control valve fitting. Tighten the tube nut to a torque of 31 Nm (275 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5699 Power Steering Pump: Service and Repair Power Steering Pump Initial Operation WARNING: The fluid level should be checked with engine off to prevent injury from moving components. Use only Mopar (R) Power Steering Fluid. Do not use automatic transmission fluid. Do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal temperature of approximately 21° C to 27°C (70°F to 80°F). 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 2. Start the engine and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 6. Add power steering fluid if necessary. 7. Lower the vehicle and turn the steering wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and refill as required. 9. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5700 Power Steering Pump: Service and Repair Power Steering Pump Mounting Bracket Replacement DISASSEMBLE 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. 2. Mount Puller, Special Tool C-4333 or C-4068, or equivalents on power steering pump pulley. Mount power steering pump and puller in a vise to keep shaft of power steering pump from turning when removing pulley. 3. Remove the drive pulley from the shaft of the power steering pump. 4. Remove bolts attaching power steering pump to mounting bracket. 5. Remove power steering pump from mounting bracket. ASSEMBLE 1. Install power steering pump on mounting bracket. Install the power steering pump to mounting bracket attaching bolts. Torque the mounting bolts to 54 Nm (40 ft. lbs). 2. Place power steering pump pulley squarely on end of power steering pump shaft. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5701 3. Place Installation Spacer, Special Tool 6936, or equivalent on top of the power steering pump pulley. Fig. 43 4. Mount Installer, Special Tool C-4063, or equivalent in internal threads of the power steering pump shaft and against Special Tool 6936 on power steering pump pulley. 5. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until Special Tool 6936 is against the end of the shaft. When Special Tool 6936 is against the shaft of the power steering pump, Special Tool C-4063, or equivalent will no longer be able to be turned. 6. Remove Installer, Special Tool C-4063, or equivalent from power steering pump. 7. Install power steering pump and bracket assembly back on engine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5702 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement NOTE: The power steering pump must be removed from the vehicle for removal of the power steering pump pulley. REMOVE 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. 2. Mount Puller, Special Tool C-4333 or C-4068, or equivalents on power steering pump pulley. Mount power steering pump and puller in a vise to keep shaft of power steering pump from turning when removing pulley. 3. Remove the drive pulley from the shaft of the power steering pump. 4. Replace power steering pump pulley if bent, cracked, or loose. INSTALL 1. Mount power steering pump in a vise using the power steering pump mounting bracket. 2. Place power steering pump pulley squarely on end of power steering pump shaft. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5703 3. Place Installation Spacer, Special Tool 6936, or equivalent on top of the power steering pump pulley. Fig. 43 4. Mount Installer, Special Tool C-4063, or equivalent in internal threads of the power steering pump shaft and against Special Tool 6936 on power steering pump pulley. 5. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until Special Tool 6936, or equivalent is against the end of the power steering pump shaft. When Special Tool 6936 is against the shaft of the power steering pump Special Tool C-4063, or equivalent will no longer be able to be turned. 6. Remove Installer, Special Tool C-4063, or equivalent from power steering pump. 7. Install power steering pump and mounting bracket back on engine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5704 Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Seal Replacement NOTE: The power steering pump does not require removal from the engine for removal and replacement of the flow control valve fitting O-Ring. REMOVAL 1. Remove the power steering fluid pressure hose from power steering pump pressure fitting. 2. Remove the power steering pump discharge/ flow control valve fitting from the power steering pump housing. Use care to prevent the flow control valve and spring from sliding out of the discharge/flow control valve fitting. 3. Remove and discard O-ring seal from fitting. INSTALLATION 1. If necessary, clean and install flow control valve and spring in pump housing bore. 2. Install new O-ring seal on fitting. 3. Install the discharge/flow control valve fitting into the power steering pump. Tighten the discharge/flow control valve to a torque of 75 Nm (65 ft. lbs.). 4. Install power steering fluid pressure hose on flow control valve fitting. Tighten the tube nut to a torque of 31 Nm (275 inch lbs.). Power Steering Pump Initial Operation WARNING: The fluid level should be checked with engine off to prevent injury from moving components. Use only Mopar (R) Power Steering Fluid. Do not use automatic transmission fluid. Do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal temperature of approximately 21° C to 27°C (70°F to 80°F). 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 2. Start the engine and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5705 4. Raise the front wheels off the ground. 5. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 6. Add power steering fluid if necessary. 7. Lower the vehicle and turn the steering wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and refill as required. 9. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Power Steering Pump Mounting Bracket Replacement DISASSEMBLE 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. 2. Mount Puller, Special Tool C-4333 or C-4068, or equivalents on power steering pump pulley. Mount power steering pump and puller in a vise to keep shaft of power steering pump from turning when removing pulley. 3. Remove the drive pulley from the shaft of the power steering pump. 4. Remove bolts attaching power steering pump to mounting bracket. 5. Remove power steering pump from mounting bracket. ASSEMBLE 1. Install power steering pump on mounting bracket. Install the power steering pump to mounting bracket attaching bolts. Torque the mounting bolts to 54 Nm (40 ft. lbs). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5706 2. Place power steering pump pulley squarely on end of power steering pump shaft. 3. Place Installation Spacer, Special Tool 6936, or equivalent on top of the power steering pump pulley. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5707 Fig. 43 4. Mount Installer, Special Tool C-4063, or equivalent in internal threads of the power steering pump shaft and against Special Tool 6936 on power steering pump pulley. 5. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until Special Tool 6936 is against the end of the shaft. When Special Tool 6936 is against the shaft of the power steering pump, Special Tool C-4063, or equivalent will no longer be able to be turned. 6. Remove Installer, Special Tool C-4063, or equivalent from power steering pump. 7. Install power steering pump and bracket assembly back on engine. Power Steering Pump Pulley Replacement NOTE: The power steering pump must be removed from the vehicle for removal of the power steering pump pulley. REMOVE 1. Remove power steering pump from engine. CAUTION: Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley. This will damage the pulley and the power steering pump. 2. Mount Puller, Special Tool C-4333 or C-4068, or equivalents on power steering pump pulley. Mount power steering pump and puller in a vise to keep shaft of power steering pump from turning when removing pulley. 3. Remove the drive pulley from the shaft of the power steering pump. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5708 4. Replace power steering pump pulley if bent, cracked, or loose. INSTALL 1. Mount power steering pump in a vise using the power steering pump mounting bracket. 2. Place power steering pump pulley squarely on end of power steering pump shaft. 3. Place Installation Spacer, Special Tool 6936, or equivalent on top of the power steering pump pulley. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5709 Fig. 43 4. Mount Installer, Special Tool C-4063, or equivalent in internal threads of the power steering pump shaft and against Special Tool 6936 on power steering pump pulley. 5. Ensuring that special tool and pulley remain aligned with pump shaft, force pulley onto power steering pump shaft until Special Tool 6936, or equivalent is against the end of the power steering pump shaft. When Special Tool 6936 is against the shaft of the power steering pump Special Tool C-4063, or equivalent will no longer be able to be turned. 6. Remove Installer, Special Tool C-4063, or equivalent from power steering pump. 7. Install power steering pump and mounting bracket back on engine. Installation The content of this article reflects changes changes called for in TSB 26-11-97. 1. Install power steering pump, mounting bracket and fluid supply hose as an assembly back in vehicle, using reverse order of removal. Be sure power steering fluid supply hose is correctly routed up to the power steering fluid reservoir when installing power steering pump. 2. Before fastening the pump to the accessory drive bracket, fasten the bracket to the rear of the engine with 3 bolts. Then, loosely install pump mounting bolts at front adjusting slot and top of power steering pump front bracket to accessory drive bracket and engine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5710 3. Loosely install the bolt mounting power steering pump to its rear mounting bracket. 4. Using a lint free towel, wipe clean all open power steering hose ends, and power steering pump fittings. 5. Install a new O-ring on end of power steering pressure hose fitting. 6. Lubricate both O-rings using fresh clean power steering fluid. 7. Install the power steering pressure hose in the power steering pump pressure fitting. Loosely install tube nut into pressure fitting on power steering pump. Pressure hose must be installed between the front bracket of the power steering pump and power steering pump pulley. 8. Install power steering pump drive belt on power steering pump pulley. 9. Install a 1/2 inch breaker bar in the square adjusting hole in the front power steering pump mounting bracket. Then rotate pump to obtain the correct drive belt tension. When correct drive belt tension is obtained first tighten the bottom 2 adjusting slot bolts at the power steering pump cast mounting bracket to a torque of 54 Nm (40 ft. lbs.). Then tighten the power steering pump mounting bracket top pivot bolt to a torque of 54 Nm (40 ft lbs). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5711 10. Position power steering pressure hose in outlet fitting of power steering pump, so hose is not contacting the pulley of power steering pump drive belt. The tighten tube nut to a torque of 31 Nm (275 inch lbs.). 11. Install heat shield on hydraulic control unit for the antilock brake system. 12. Install accessory drive splash shield in right front inner fender. 13. Install tire back on vehicle. Tighten the wheel lug nuts in proper sequence until all lug nuts are torqued to half specification. Then repeat tightening sequence to full specified torque of 129 Nm (95 ft. lbs). 14. Lower vehicle. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5712 15. Install power steering fluid supply hose on power steering fluid reservoir fitting. Install hose clamp on hose, being sure hose clamp is installed on hose past upset bead on power steering fluid reservoir. 16. Fill power steering reservoir to correct fluid level. 17. Connect negative cable back on negative post of battery. 18. Start the engine and let run for a few seconds. Then turn the engine off. 19. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 20. Raise front wheels of vehicle off the ground. 21. Start engine, then slowly turn steering wheel right and left several times until lightly contacting the wheel stops. Then turn the engine off. 22. Add power steering fluid if necessary. 23. Lower the vehicle. Start engine again and turn the steering wheel slowly from lock to lock. 24. Stop the engine. Check the fluid level and refill as required. 25. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 26. After power steering pump is installed, check for leaks at all hose connections and power steering pump fittings. Removal The content of this article reflects changes changes called for in TSB 26-11-97. WARNING: Power steering oil, engine components and exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses, or allow hoses to touch hot exhaust manifold or catalyst. 1. Remove battery cable from (-) negative post on battery and isolate cable. 2. Siphon as much power steering fluid as possible out of the remote power steering fluid reservoir. 3. Remove the power steering fluid supply hose from the power steering fluid reservoir. Fluid supply hose will be removed with the power steering pump. 4. Raise vehicle. 5. Remove right front tire from vehicle. 6. Remove accessory drive splash shield from the right front wheel well. 7. Remove the power steering fluid pressure hose from pressure fitting on power steering pump. Let remaining power steering fluid drain out of the Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5713 power steering fluid supply hose, power steering pump and power steering fluid pressure hose. After power steering fluid has drained out of pump and hose, install a cap on the power steering pressure hose and a plug in the power steering pump pressure fitting. 8. Remove the antilock brakes hydraulic control unit heat shield from the hydraulic control unit mounting bracket. 9. Remove bolt at adjusting slot in accessory drive mounting bracket, attaching back of power steering pump to the bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 5714 10. Remove bolt at adjustment slot, attaching the power steering pump front mounting bracket to cast aluminum accessory drive bracket on engine. Then remove bolt at top of power steering front mounting bracket, attaching it to the accessory drive bracket. 11. Remove the 2 upper and 1 lower bolts fastening the accessory drive bracket to the rear of the engine. Allow bracket to move freely away from pump. 12. Remove drive belt from the pump pulley, then remove power steering pump, fluid supply hose and front mounting bracket as an assembly from the engine and vehicle. This assembly is removable by rotating it out through the area between rear of engine, driveshaft and front suspension crossmember. 13. Transfer required parts from removed power steering pump, to replacement power steering pump. Suction Port Fitting Replacement NOTE: The power steering pump will require removal from the engine for removal and replacement of the suction port O-Ring seal. REMOVAL 1. Remove power steering fluid supply hose from power steering pump suction port fitting. 2. Remove bolt attaching the power steering pump suction port fitting to the power steer 3. Remove the suction port fitting from the power steering pump. 4. Remove and discard O-ring seal from suction port fitting. INSTALLATION 1. Install new O-ring seal on suction fitting. 2. Install suction port fitting in power steering pump. Install and securely tighten the suction port fitting attaching bolt. 3. Install power steering fluid supply hose on suction port fitting, being sure hose clamp is installed on hose past upset bead on suction port fitting. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Service and Repair > Solenoid Control Valve Module Replacement Power Steering Valve: Service and Repair Solenoid Control Valve Module Replacement GENERAL INFORMATION The solenoid control module is mounted on the steering gear assembly fluid lines using attaching clips on back of module. The solenoid control module is removable from the steering gear for servicing, without removing steering gear from vehicle. REMOVE 1. Remove wiring harness connectors from solenoid control module. 2. Unclip locking tab on bottom side of solenoid control module, holding control module to steering gear fluid lines. Then-rotate control module upward and remove the upper 2 attaching clips from the steering gear fluid lines. INSTALL 1. Hook upper tabs on solenoid control module onto upper steering gear fluid line. Then rotate module downward until locking tab on bottom of module is locked on lower power steering gear fluid line. 2. Connect wiring harness connectors onto solenoid control module. Be sure wiring harness connector seals are on connectors and in good condition before installing connectors on control module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Service and Repair > Solenoid Control Valve Module Replacement > Page 5719 Power Steering Valve: Service and Repair Solenoid Control Valve Replacement GENERAL INFORMATION If a solenoid control valve needs to be replaced on the speed proportional steering gear, the steering gear will need to be removed from the vehicle. REMOVE 1. Remove electrical connector to the solenoid control valve, at solenoid control module. 2. Using a 1 5/16 inch crow foot loosen solenoid control valve from steering gear. Then remove solenoid control valve from power steering gear. INSTALL 1. Inspect O-ring seals on solenoid control valve to be sure they are not damaged. If O-rings are not damaged, moisten O-rings using only fresh clean Mopar, Power Steering Fluid or equivalent. 2. Install solenoid control valve into steering gear by hand, until solenoid is fully seated into the steering gear. 3. Using a 1 5/16 inch crow foot torque the solenoid control valve to 14 Nm (124 inch lbs.). 4. Connect wiring harness connector from solenoid control valve onto solenoid control module. Be sure wiring harness connector seal are on connector is in good condition before installing connector on control module. 5. Road test vehicle or refer to the test using the DRB scan tool, to confirm correct operation of the variable-assist speed-proportional power steering gear. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 5723 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 5728 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revision NUMBER: 26-10-96 GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus, Stratus & Breeze - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Wiring diagram revisions to the connector pin-outs 8W-80-44 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 5734 8W-80-45 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 5735 8W-80-46 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revision > Page 5736 8W-80-47 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 5739 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5740 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5741 Power Steering Pressure Switch: Description and Operation Fig. 21 Power Steering Pressure Switch PURPOSE On some vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. OPERATION The pressure switch improves vehicle idle quality, by maintaining required engine idle speed when necessary, do to increased pressure in the power steering system. This increased pressure will slow down the power steering pump which will decrease engine idle speed. The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed will be maintained. The maintained engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. The power steering pressure switch is mounted directly to the power steering gear on vehicle's requiring its usage. When power steering pump pressure exceeds 4137 kPa (600 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z1 provides a ground for the power steering pressure switch. The ground is terminated at the left strut tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5742 Power Steering Pressure Switch: Service and Repair REMOVE 1. Disconnect negative battery cable from the negative post of the battery. Be sure cable is isolated from negative post on battery. 2. Raise vehicle. 3. Locate power steering pressure switch on the back side of the power steering gear. 4. Remove the vehicle's wiring harness connector from the power steering pressure switch. 5. Using a crow foot and long extension, remove power steering pressure switch, from power steering gear. CAUTION: When tightening the power steering pressure switch after installation in steering gear, do not exceed the torque specification shown in step 1 below. Over-tightening may result in stripping the threads out of the pressure switch port on the steering gear. INSTALL 1. Install power steering pressure switch into power steering gear by hand until fully seated. Then using a crow foot and extension, tighten power steering pressure switch to a torque of 16 Nm (12 ft. lbs.). 2. Install vehicle wiring harness connector onto power steering pressure switch. Be sure latch on wiring harness connector is fully engaged with locking tab on power steering pressure switch. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 3. Fill power steering reservoir to correct fluid level. 4. Connect negative cable back on negative post of battery. 5. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 5747 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. ARMING 1. Connect battery ground cable. 2. From PASSENGER side of vehicle, turn ignition switch to ON position. 3. The SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 4. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair REMOVAL 1. Remove three lower cover attaching screws. 2. Remove five knee bolster mounting screws and remove bolster. 3. Remove upper and lower covers. 4. If removing the upper half only: a. Remove lower cover attaching screws. b. Loosen the lower part of instrument cluster hood for clearness as necessary. c. Remove upper cover. INSTALLATION 1. For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications To Suspension Crossmember ............................................................................................................. ....................................................... 68 Nm (50 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Standard Steering Gear Steering Gear: Description and Operation Standard Steering Gear The power steering system consists of these six major components. Power Steering Pump, Power Steering Gear, Power Steering Reservoir, Power Steering Supply and Pressure Hoses, and Power Steering Fluid Return Hose. Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth. Power assist steering is provided by an open center, rotary type control valve which directs oil from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. This movement directs oil behind the integral rack piston, which, in turn, builds up hydraulic pressure and assists in the turning effort. The drive tangs on the pinion of the power steering pump mate loosely with a stub shaft. This is to permit manual steering control to be maintained if the drive belt on the power steering pump should break. However, under these conditions, steering effort will be increased. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Standard Steering Gear > Page 5756 Steering Gear: Description and Operation Speed Proportional Steering Gear Available as an option or as standard equipment on certain vehicles is electronically controlled, variable-assist speed-proportional power steering. Variable-assist speed-proportional power steering, provides additional steering assist while the vehicle is stationary and at slow driving speeds. This additional power steering assist reduces the steering effort required by the driver for low speed driving and parking maneuvers. Variable-assist speed-proportional power steering, then provides less power steering assist at highway speeds, to maintain the firm, responsive feel of the existing non variable assist speed proportional power steering system. The operational range of the variable-assist speed proportional power steering system, is from zero to approximately 60 mph. Maximum available power steering assist is provided at zero miles per hour. The power steering assist is then gradually reduced from vehicle speeds of greater then zero to a maximum speed of approximately 60mph. The minimum power steering assist available, is reached at a vehicle speed of approximately 60 mph. Variable-assist power steering, is provided by controlling power steering fluid pressure at the power steering gear. The pressure is controlled, by regulating power steering fluid flow from the steering gear back to the power steering pump. A solenoid valve located on the steering gear, is used to control power steering pressure, by varying the size of an orifice which the power steering fluid must flow through, from the steering gear back to the power steering pump. The variable-assist speed-proportional solenoid control valve is controlled by the steering gear mounted electronic Solenoid Control Module (SCM). The SCM receives the vehicle speed signal sent from the Transmission Control Module (TCM). Upon receiving the vehicle speed signal from the TCM, the SCM converts that speed signal into an electrical current usable by the solenoid control valve for controlling the variable assist of the power steering system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Standard Steering Gear: Testing and Inspection Standard Fig.4 Pressure Gauge Tool Connections GENERAL INFORMATION The following procedure can be used to test the operation of the power steering system on the vehicle. This test will provide the flow rate of the power steering pump along with the maximum relief pressure. This test is to be performed any time a power steering system problem is present to determine if the power steering pump or power steering gear is not functioning properly. The following pressure and flow test is performed using Pressure/Flow Tester, Special Tool 6815, or equivalent. FLOW AND PRESSURE TEST PROCEDURE 1. Check power steering pump drive belt tension and adjust as necessary. 2. Disconnect power steering fluid pressure hose, at power steering pump. Use a container for dripping fluid. 3. Connect Pressure Gauge, Special Tool from kit 6815, or equivalent to both hoses using adapter fittings. Connect spare pressure hose, to power steering pump pressure hose banjo fitting. 4. Completely open valve on Special Tool 6815, or equivalent. 5. Start engine and let idle long enough to circulate power steering fluid through flow/pressure test and get air out of fluid. Then shut off engine. 6. Check power steering fluid level, and add fluid as necessary. Start engine again and let idle. 7. Pressure gauge should read below 862 kPa (125 psi), if above, inspect the hoses for restrictions and repair as necessary. The initial pressure reading should be in the range of 345 - 552 kPa (50 - 80 psi). The flow meter should read between 1.3 and 1.4 GPM. CAUTION: The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation. Do not leave valve closed for more than 5 seconds as the pump could be damaged. 8. Close valve fully three times and record highest pressure indicated each time. All three readings must be above specifications and within 345 kPa (50 psi) of each other. NOTE: Power steering pump maximum relief pressure is 8240 - 8920 kPa (1195 - 1293 psi.). If power steering pump pressures above specifications but not within 345 kPa (50 psi) of each other, then replace power steering pump. - If pressures within 345 kPa (50 psi) of each other but below specifications, then replace power steering pump. CAUTION: Do not force the pump to operate against the stops for more than 5 seconds at a time because, pump damage will result. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Standard > Page 5759 9. Open test valve. Turn steering wheel to the extreme left and right positions until against the stops, recording the highest indicated pressure at each position. Compare pressure gauge readings to power steering pump specifications. If highest output pressures are not the same against either stop, the steering gear is leaking internally and must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Standard > Page 5760 Steering Gear: Testing and Inspection Speed Proportional Steering The variable assist speed proportional power steering system, is diagnosed if suspected of not functioning properly, using the Diagnostic Readout Box (DRB) scan tool. The test consists of checking available power steering assist, using the DRB scan tool, to create an electronically simulated vehicle speed of 0 and 60 mph. The solenoid control valve and solenoid control module are both serviceable components of the variable assist speed proportional power steering gear assembly. Both components are replaceable without requiring removal of the steering gear from the vehicle. Refer to the specific component service in the section for the required replacement procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement Steering Gear: Service and Repair Steering Gear Replacement Removal 1. Remove remote ground cable from ground stud on shock tower. Then correctly isolate ground cable from vehicle by installing isolator on stud. 2. Siphon as much power steering fluid as possible from the remote power steering fluid reservoir. 3. From interior of vehicle, remove the retaining pin from the intermediate shaft coupler pinch bolt. Then remove the pinch bolt from the intermediate shaft coupler and the separate intermediate shaft coupler, from steering gear shaft 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Remove both front wheel and tire assemblies from the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5763 6. Remove nuts attaching both outer tie rod ends to the steering knuckles. Nuts are to be removed from tie rod ends using the following procedure, hold tie rod end stud with an 11/32 socket, while loosening and removing nut with wrench. 7. Remove-both tie rod end studs, from the steering knuckles, using Remover, Special Tool MB-991113. CAUTION: This vehicles is designed and assembled using NET BUILD front suspension alignment settings. This means that front suspension alignment settings are determined as the vehicle is designed by the location of front suspension components in relation to the vehicle body. This process is carried out when building the vehicle, by accurately locating the front suspension crossmember, to master gage holes located in the underbody of the vehicle. With this method of designing and building a vehicle, it is no longer necessary or possible to adjust a vehicles front suspension alignment settings. Due to this, whenever the front suspension crossmember is removed from a vehicle, it MUST be replaced in the same location on the body of the vehicle it was removed from. Front suspension Toe settings though are still adjustable by the outer tie rod ends. CAUTION: Before removing the front suspension crossmember from the vehicle, locating marks for the front suspension crossmember MUST be scribed on the front suspension crossmember and body of vehicle. This must be done so front suspension crossmember can be located against body of vehicle, in the same location when it is installed back in vehicle. If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assembled, NET BUILD front suspension alignment settings will not be obtained. This may lead to handling and or tire wear problems. NOTE: Use the following procedure to mark the side to side and front to back installed location of the front suspension crossmember to the body of the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5764 8. Using an awl, scribe a line on the body marking the front to back installed location where the front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at both the front and back of where the crossmember is mounted to the vehicle and on each side of the vehicle. In the left side of the vehicle is shown. 9. Using an awl, scribe a line on the front suspension crossmember marking the side to side installed location where front suspension crossmember is mounted against the body of the vehicle. The line should be scribed at the side of the frame rail bracket where the crossmember is mounted to the vehicle. The locating mark is to be marked the same on each side of the vehicle. In the left side of the vehicle is shown. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5765 10. Remove the stabilizer bar bushing clamp to body attaching bolts only. The sway bar bushing clamp to front suspension crossmember bolts do not need to be removed 11. If vehicle is equipped with antilock brakes, the hydraulic control unit can not hang from the brake tubes when lowering front suspension crossmember. Using wire, tie the antilock brakes hydraulic control unit to the body and engine so the wire will support it when the crossmember is lowered. 12. If vehicle is equipped with antilock brakes, remove the 3 bolts attaching the antilock brakes hydraulic control unit to the front suspension crossmember. 13. Remove the bolts attaching the shock absorber clevis to the left and right lower control arms. 14. Remove the 2 bolts attaching the under engine support bracket to the front edge of the front suspension crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5766 15. Remove the 2 attaching bolts from the rear support bracket at the rear of the front suspension crossmember. 16. Remove bolt attaching engine support bracket to the transaxle mounting bracket. 17. Position a transmission jack under the center of the front suspension crossmember. Transmission jack is used to lower, support and raise front suspension crossmember when removing steering gear assembly. 18. From each side of the vehicle, remove the 2 bolts attaching the front and rear of the front suspension crossmember to the frame rails of vehicle. 19. Using transmission jack, lower front suspension crossmember enough to allow steering gear to be removed from crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms, weight of crossmember must be supported by the transmission jack. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5767 20. Remove power steering fluid, pressure and return hoses from the power steering gear assembly. 21. Remove wiring harness connector, from the power steering fluid pressure switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5768 22. Remove the 2 bolts, at the isolators attaching the steering gear assembly to front suspension crossmember. Then remove the 2 bolts attaching the steering gear saddle bracket to the front suspension crossmember. Remove the steering gear assembly from the front suspension crossmember. 23. Transfer required parts from removed steering gear assembly to the replacement steering gear, if a new steering gear is being installed. Installation Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5769 1. Install steering gear assembly on front suspension crossmember. Install the 2 long steering gear assembly to front crossmember mounting bolts into the mounting isolators. Then install the 2 short bolts into the saddle bracket. Tighten the 4 steering gear mounting bolts to a torque of 68 Nm (50 ft. lbs.). 2. Install the power steering fluid pressure and return lines on the ports of the power steering gear. Tighten power steering fluid pressure and return lines to steering gear tube nuts to a torque of 31 Nm (275 inch lbs.). 3. Using transmission jack, raise front suspension crossmember and steering gear against body of vehicle. Start the 2 rear bolts into tapping plates, attaching front suspension crossmember to body of vehicle. Then install the 2 front bolts, attaching front suspension crossmember to frame rails of vehicle. Tighten the 4 mounting bolts evenly until front suspension crossmember is against body of vehicle at the 4 mounting points. Then torque the 4 mounting bolts to 2 Nm (20 inch lbs.) to hold front suspension crossmember in position. CAUTION: When front suspension crossmember is installed back in vehicle, crossmember MUST be aligned with positioning marks previously scribed into body of vehicle. This MUST be done to maintain NET BUILD front suspension alignment settings. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5770 4. Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the previously scribed positioning marks on body of vehicle. When front suspension crossmember is correctly: positioned, torque the 2 rear crossmember mounting bolts to 163 Nm (120 ft. lbs.). Then torque the 2 front crossmember to frame rail attaching bolts to 163 Nm (120 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5771 5. Install the engine support bracket on the front of the front suspension crossmember. Install the 2 support bracket to suspension crossmember attaching bolts and tighten to a torque of 75 Nm (55 ft. lbs.). 6. Install bolt attaching engine support bracket to transaxle mounting bracket. Tighten bolt to a torque of 75 Nm (55 ft. lbs.). 7. Install the 2 bolts attaching the rear support bracket, for the under engine support bracket, to the rear of the front suspension crossmember. Tighten bolts to a torque of 75 Nm (55 ft. lbs.). 8. Install vehicle wiring harness connector onto power steering fluid pressure switch on steering gear assembly. Be sure locking tab on wiring harness connector is securely latched to pressure switch. 9. Install the antilock brakes hydraulic control unit mounting bracket on the front suspension cross member. Install the 3 mounting bracket to crossmember attaching bolts and tighten to a torque of 28 Nm (250 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5772 10. Loosely install the 2 shock absorber clevis to lower control arm attaching nuts and bolts. 11. Install tie rod seal boot heat shield on tie rod end. 12. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 61 Nm (45 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5773 13. Install the 2 stabilizer bar bushing clamp to body attaching bolts and securely tighten. CAUTION: When supporting lower control arm with jack stand, do not position jack stand under the ball joint cap on the lower control arm. Position in area of lower control arm shown. 14. Lower vehicle to the ground with a jack stand positioned under the lower control arm. Continue to lower vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm. 15. Tighten the shock absorber clevis to lower control arm bushing thru-bolt to a torque of 92 Nm (68 ft. lbs.). 16. Install the wheel and tire assemblies back on vehicle. Tighten the wheel nuts in proper sequence to a torque of 129 Nm (95 ft. lbs.) torque. CAUTION: Before connecting steering column intermediate shaft coupler onto steering gear shaft, front wheels must be pointed straight ahead and steering wheel must be in center position. 17. From interior of vehicle, reconnect the steering column intermediate shaft coupler on the steering gear shaft. Install steering gear coupler retaining pinch bolt and torque to 27 Nm (240 inch lbs.). Be sure to install the upper to lower steering coupler retaining bolt, retention pin. CAUTION: Do not use automatic transmission fluid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5774 18. Fill power steering pump fluid reservoir to the (Full-Cold) proper level. 19. Start the engine and let run for a few seconds. Then turn the engine off. 20. Add fluid if necessary. 21. Raise front wheels of vehicle off the ground. 22. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Fill pump reservoir to correct level with Mopar, Power Steering Fluid, or equivalent. 23. Lower front wheels of vehicle back on the ground. CAUTION: During this procedure do not allow the steering gear inner tie rod boots to become twisted. 24. Check front alignment and adjust the front Toe setting on the vehicle. 25. Tighten tie rod jam nut to 74 Nm (55 ft.lbs.) torque. 26. Adjust steering gear to tie rod boots at tie rods. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5775 Steering Gear: Service and Repair Mounting Bolt Isolator Replacement NOTES: - The removal and installation of the mounting bolt isolator must be performed with the steering gear assembly removed from the vehicle. - The steering gear mounting bolt isolators are a serviceable component of the steering gear assembly. Both isolator bushing are serviced using the same procedure listed below but only the rear mounting bushing is shown. REMOVE 1. Using a screwdriver, pry the sleeve out of the mounting bolt isolator. 2. Pry the mounting bolt isolator bushing from the steering gear mounting bracket. INSTALL 1. Lubricate replacement mounting bolt isolator bushing using Mopar (R), Silicone Spray Lube or an equivalent. 2. Install the mounting bolt isolator bushing into the steering gear mounting bracket from the bottom side of the bracket. 3. Install mounting bolt isolator bushing sleeve into isolator bushing by pressing the sleeve into the bushing by hand. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column Clunking Or Rattle Technical Service Bulletin # 19-02-99A Date: 991022 Steering Wheel/Steering Column - Clunking Or Rattle NUMBER: 19-02-99 Rev. A GROUP: Steering DATE: Oct. 22, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-01-98 DATED FEBRUARY 6, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003) AND 19-02-99 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISION ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS CHANGES. SUBJECT: Clunking Or Rattle In Steering Wheel/Steering Column OVERVIEW: This bulletin involves resetting the steering column preload. MODELS: 1995 - **2000** (JA) Breeze/Cirrus/Stratus 1996 - **2000** (JX) Sebring Convertible 1995 - 2000 (PL) Neon SYMPTOM/CONDITION: Steering wheel/column clunking or rattle is more frequent while hitting bumps or on hard turns. DIAGNOSIS: Inspect steering wheel/column for any rattle or clunking noise. If symptoms exist perform the Repair Procedure. PARTS REQUIRED: 1 05015627AA Bolt, Steering Gear Coupler Retaining, PL 1 **06506112AA Bolt, Steering Gear Coupler Retaining, JA/JX** 1 **06036212AA Clip, Steering Gear Coupler Retaining, JA/JX** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-96 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE VEHICLE WHEELS NEED TO BE ON THE GROUND (SUPPORTING VEHICLE WEIGHT) WHEN PERFORMING THIS REPAIR. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with a tilt steering column, adjust to the full up position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column Clunking Or Rattle > Page 5784 3. Detach the lower steering column intermediate shaft from the steering gear shaft (Figure 1). This allows the steering column preload to reset. 4. Re-attach the intermediate shaft to the steering gear using a new pinch bolt from the Parts Required section of this bulletin. Tighten the bolt to 27 N.m (240 in. lbs.). 5. Install the retaining clip/pin into the pinch bolt (Figure 1). NOTE: A NEW STEERING GEAR COUPLING PINCH BOLT MUST BE USED WHEN RE-ATTACHING THE INTERMEDIATE SHAFT TO THE STEERING GEAR. THIS BOLT HAS A LOCKING PATCH THAT IS DESTROYED WHEN THE NUT IS REMOVED. 6. Connect the battery negative cable and reset the clock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column - Clunking Or Rattle Technical Service Bulletin # 19-02-99A Date: 991022 Steering Wheel/Steering Column - Clunking Or Rattle NUMBER: 19-02-99 Rev. A GROUP: Steering DATE: Oct. 22, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-01-98 DATED FEBRUARY 6, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003) AND 19-02-99 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISION ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS CHANGES. SUBJECT: Clunking Or Rattle In Steering Wheel/Steering Column OVERVIEW: This bulletin involves resetting the steering column preload. MODELS: 1995 - **2000** (JA) Breeze/Cirrus/Stratus 1996 - **2000** (JX) Sebring Convertible 1995 - 2000 (PL) Neon SYMPTOM/CONDITION: Steering wheel/column clunking or rattle is more frequent while hitting bumps or on hard turns. DIAGNOSIS: Inspect steering wheel/column for any rattle or clunking noise. If symptoms exist perform the Repair Procedure. PARTS REQUIRED: 1 05015627AA Bolt, Steering Gear Coupler Retaining, PL 1 **06506112AA Bolt, Steering Gear Coupler Retaining, JA/JX** 1 **06036212AA Clip, Steering Gear Coupler Retaining, JA/JX** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-96 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE VEHICLE WHEELS NEED TO BE ON THE GROUND (SUPPORTING VEHICLE WEIGHT) WHEN PERFORMING THIS REPAIR. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with a tilt steering column, adjust to the full up position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column - Clunking Or Rattle > Page 5790 3. Detach the lower steering column intermediate shaft from the steering gear shaft (Figure 1). This allows the steering column preload to reset. 4. Re-attach the intermediate shaft to the steering gear using a new pinch bolt from the Parts Required section of this bulletin. Tighten the bolt to 27 N.m (240 in. lbs.). 5. Install the retaining clip/pin into the pinch bolt (Figure 1). NOTE: A NEW STEERING GEAR COUPLING PINCH BOLT MUST BE USED WHEN RE-ATTACHING THE INTERMEDIATE SHAFT TO THE STEERING GEAR. THIS BOLT HAS A LOCKING PATCH THAT IS DESTROYED WHEN THE NUT IS REMOVED. 6. Connect the battery negative cable and reset the clock. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5791 Steering Wheel: Specifications Retaining Nut ....................................................................................................................................... ..................................................... 61 Nm (45 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair REMOVE 1. Remove front wheel and tire assembly from the vehicle. 2. Remove nuts attaching both outer tie rod ends to the steering knuckles. Nuts are to be removed from tie rod ends using the following procedure, hold tie rod end stud with an 11/32 socket, while loosening and removing nut with wrench. 3. Remove-both tie rod ends from the steering knuckles, using Remover, Special Tool MB-991113, or equivalent. 4. Loosen the inner to outer tie rod jam nut. Remove the outer tie rod from inner tie rod. 5. Remove jam nut from inner tie rod. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair > Page 5796 6. Using pliers expand tie rod boot clamp, and remove clamp from steering gear boot. 7. Remove the inner tie rod boot to steering gear clamp. NOTE: After removing inner boot clamps. Use a very small screwdriver to lift boot from its retaining groove in steering gear. Then the boot can be removed from steering gear. INSTALL 1. Install tie rod boot to steering gear clamp on tie rod boot. Then install tie rod boot on inner tie rod. 2. Crimp inner tie rod boot to steering gear clamp on tie rod boot using Crimper, Special Tool, C4975-A, or equivalent. When installing clamp, Special Tool C4975-A, or equivalent must have bottom bolt tightened until their is no gap between the 2 bars of the tool. 3. Lubricate inner tie rod boot groove with silicone type lubricant, then install tie rod boot to inner tie rod clamp. (Clamp will have to be loosened for toe adjustment.) 4. Install inner to outer tie rod jam nut on inner tie rod. 5. Install outer tie rod on inner tie rod. Do not tighten jam nut. 6. Install steering gear assembly back in the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair > Page 5797 7. Install tie rod end seal boot heat shield on the tie rod end. 8. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 61 Nm (45 ft. lbs.). CAUTION: During this procedure do not allow the steering gear boot to become twisted. 9. Make toe adjustment by turning inner tie rod. 10. Tighten the inner to outer tie rod jam nut to 75 Nm (55 ft. lbs.) torque. Lubricate tie rod boot groove with silicone type lubricant, before installing outer boot clamp, making sure boot is not twisted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 02-05-98 > May > 98 > Tie Rod End - Intermittent Popping Noise Tie Rod End: Customer Interest Tie Rod End - Intermittent Popping Noise NO: 02-05-98 GROUP: Suspension DATE: May 29, 1998 SUBJECT: Intermittent Popping Noise in Front End MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DEC. 31, 1997 (MDH 1231XX). SYMPTOM/CONDITION: Intermittent popping sound coming from the front of the vehicle may be heard from either side. The popping can also be felt in the steering wheel and sometimes in the floor. This condition usually occurs during warm ambient temperatures after driving the vehicle for at least 5-10 miles (8-16 km) on smooth road surfaces. The noise will occur without steering input or suspension travel. Once the sound begins it may be intermittent to continuous. Stopping the vehicle and large turning angles may cause the sound to subside. The vehicle may have to be driven for another 5-10 miles before the sound returns. DIAGNOSIS: Test drive the vehicle on a smooth road surface and listen for a popping sound from the steering column to the steering gear connection. When the sound is heard it may be felt in the steering wheel and/or the floor. If available, use a sound listening device such as a Pentastar Service Equipment ChassisEAR(R), p/n W-06600, to pinpoint the sound origination. If the sound is coming from the tie rod end(s), perform the Repair Procedure, otherwise further diagnosis will be required. PARTS REQUIRED: 1 04796864 End, Tie Rod, Right Side 1 04796865 End, Tie Rod, Left Side REPAIR PROCEDURE: This bulletin involves replacing both steering gear tie rod ends. 1. Using the procedure outlined on pages 19-50 through 19-51 of the 1998 Cirrus/Stratus/Breeze service manual (Publication No. 81-270-8121) or pages 19-41 through 19-42 of the 1998 Sebring Convertible service manual (Publication No. 81-270-8122). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-63-01-91 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 02-05-98 > May > 98 > Tie Rod End Intermittent Popping Noise Tie Rod End: All Technical Service Bulletins Tie Rod End - Intermittent Popping Noise NO: 02-05-98 GROUP: Suspension DATE: May 29, 1998 SUBJECT: Intermittent Popping Noise in Front End MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE DEC. 31, 1997 (MDH 1231XX). SYMPTOM/CONDITION: Intermittent popping sound coming from the front of the vehicle may be heard from either side. The popping can also be felt in the steering wheel and sometimes in the floor. This condition usually occurs during warm ambient temperatures after driving the vehicle for at least 5-10 miles (8-16 km) on smooth road surfaces. The noise will occur without steering input or suspension travel. Once the sound begins it may be intermittent to continuous. Stopping the vehicle and large turning angles may cause the sound to subside. The vehicle may have to be driven for another 5-10 miles before the sound returns. DIAGNOSIS: Test drive the vehicle on a smooth road surface and listen for a popping sound from the steering column to the steering gear connection. When the sound is heard it may be felt in the steering wheel and/or the floor. If available, use a sound listening device such as a Pentastar Service Equipment ChassisEAR(R), p/n W-06600, to pinpoint the sound origination. If the sound is coming from the tie rod end(s), perform the Repair Procedure, otherwise further diagnosis will be required. PARTS REQUIRED: 1 04796864 End, Tie Rod, Right Side 1 04796865 End, Tie Rod, Left Side REPAIR PROCEDURE: This bulletin involves replacing both steering gear tie rod ends. 1. Using the procedure outlined on pages 19-50 through 19-51 of the 1998 Cirrus/Stratus/Breeze service manual (Publication No. 81-270-8121) or pages 19-41 through 19-42 of the 1998 Sebring Convertible service manual (Publication No. 81-270-8122). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-63-01-91 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 5811 Tie Rod End: Specifications To Steering Knuckle Nut ...................................................................................................................... .................................................... 61 Nm (45 ft. lbs.) Adjustment Jam Nuts ........................................ ........................................................................................................................................ 75 Nm (55 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 5812 Tie Rod End: Testing and Inspection SYMPTOM/CONDITION: Intermittent popping sound coming from the front of the vehicle may be heard from either side. The popping can also be felt in the steering wheel and sometimes in the floor. This condition usually occurs during warm ambient temperatures after driving the vehicle for at least 5-10 miles (8-16 km) on smooth road surfaces. The noise will occur without steering input or suspension travel. Once the sound begins it may be intermittent to continuous. Stopping the vehicle and large turning angles may cause the sound to subside. The vehicle may have to be driven for another 5-10 miles before the sound returns. DIAGNOSIS: Test drive the vehicle on a smooth road surface and listen for a popping sound from the steering column to the steering gear connection. When the sound is heard it may be felt in the steering wheel and/or the floor. If available, use a sound listening device such as a Pentastar Service Equipment ChassisEAR(R), p/n W-06600, to pinpoint the sound origination. If the sound is coming from the tie rod end(s), refer to TSB # 02-05-98, dated 05/29/98 for the repair procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End Tie Rod End: Service and Repair Outer Tie Rod End DISASSEMBLE Inner To Outer Tie Rod Jam Nut 1. Loosen inner tie rod to outer tie rod jam nut. Removing Tie Rod End Nut 2. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 5815 3. Remove tie rod end stud, from steering knuckle, using Remover, Special Tool MB-991113. 4. Remove outer tie rod end from inner tie rod by unthreading it from the inner tie rod. ASSEMBLE 1. Install outer tie rod onto inner tie rod. Make sure jam nut is on inner tie rod. 2. Do not tighten jam nut. 3. Install tie rod end seal boot heat shield on the tie rod end. Torquing Tie Rod End Attaching Nut 4. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 61 Nm (45 ft. lbs.). CAUTION: During this procedure do not allow the steering gear boot to become twisted. 5. Adjust the front Toe setting on the vehicle. 6. Tighten tie rod jam nut to 75 Nm (55 ft. lbs.) torque. 7. Adjust the steering gear to inner tie rod boots at inner tie rod if they became twisted during Toe adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 5816 Tie Rod End: Service and Repair Inner Tie Rod End The Inner Tie Rod Ends are not serviced separately from the Rack and Pinion. To service the Inner Tie Rod Ends the Rack and Pinion must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > NHTSA97V201000 > Nov > 97 > Recall 97V201000: Control Arm/Ball Joint Separation Ball Joint: Recalls Recall 97V201000: Control Arm/Ball Joint Separation The lower control arm ball joint can separate due to loss of lubrication. Separation of the ball joint could cause a loss of steering control increasing the risk of a vehicle crash. Dealers will inspect the ball joint end housing cover seal for leakage with a high pressure air tester and the rubber boot will be visually inspected for damage. If the cover seal leaks or the boot is damaged, the lower control arm will be replaced. Owner notification began December 15, 1997. 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 1-800-424-9393. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > NHTSA97V201000 > Nov > 97 > Recall 97V201000: Control Arm/Ball Joint Separation Ball Joint: All Technical Service Bulletins Recall 97V201000: Control Arm/Ball Joint Separation The lower control arm ball joint can separate due to loss of lubrication. Separation of the ball joint could cause a loss of steering control increasing the risk of a vehicle crash. Dealers will inspect the ball joint end housing cover seal for leakage with a high pressure air tester and the rubber boot will be visually inspected for damage. If the cover seal leaks or the boot is damaged, the lower control arm will be replaced. Owner notification began December 15, 1997. 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 1-800-424-9393. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint Ball Joint: Specifications Lower Ball Joint Torque Castle Nut ............................................................................................................................................ ................................................. 75 Nm (55 ft. lbs.) Ball Joint Wear Limit Steering Knuckle Maximum Movement ............................................................................................................................................. 1.5 mm (0.059 inch) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint > Page 5833 Ball Joint: Specifications Upper Ball Joint FRONT: Castle Nut ............................................................................................................................................ ................................................. 62 Nm (45 ft. lbs.) REAR: Castle Nut ............................................................................................................................................ ................................................. 67 Nm (50 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Lower Ball Joint Ball Joint: Description and Operation Lower Ball Joint The ball joint used in the lower control arm of this vehicle is a sealed for life ball joint. The ball joint can not be replaced as a separate component of the lower control arm assembly. If the ball joint is determined to be defective it will require replacement of the complete lower control arm assembly. The lower ball joint connection to the steering knuckle is achieved by an interference fit created by the tapered stud of the ball joint and a tapered hole in the steering knuckle. The ball joint stud is retained in the steering knuckle using a castle nut and a cotter pin. The cotter pin is used for positive retention of the castle nut. The lower ball joint is lubricated for life at the time it is assembled in the lower control arm. The ball joint does not require any type of additional lubrication for the life of the vehicle. No attempt should be made to ever add any lubrication to the lower ball joint. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Lower Ball Joint > Page 5836 Ball Joint: Description and Operation Upper Ball Joint The ball joint is pressed into the upper control arm and has a tapered stud for attachment to the steering knuckle. The ball joint stud is attached and locked into the steering knuckle using a castle nut and cotter pin. The ball joint is not serviceable as a separate component of the upper control arm. If the ball joint is defective it will require replacement of the entire upper control arm. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Install a dial indicator on the vehicle so it is contacting the top surface of the steering knuckle near the lower ball joint stud castle nut. 3. Grab wheel and tire assembly and push it up and down firmly. 4. Record the amount of up and down movement of the steering knuckle recorded on the dial indicator. 5. Replace lower control arm if the movement in the lower control arm exceeds 1.5 mm (0.059 inch). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 5839 Ball Joint: Testing and Inspection Upper Ball Joint With the weight of the vehicle resting on the road wheels. Grasp the grease fitting and with no mechanical assistance or added force attempt to move the grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of the upper control arm is required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement Ball Joint: Service and Repair Ball Joint Replacement Lower Ball Joint Replacement NOTE: The replacement of the lower ball joint seal boot is only allowed to be done in the event that the seal boot is damaged while performing a service procedure on the vehicle. CAUTIONS: - Under no circumstances can a lower ball joint seal boot be replaced if it is determined that the vehicle had been driven with the seal boot damaged. If the vehicle has been driven with a damaged seal boot contamination of the ball joint has occurred. When contamination of the ball joint has occurred the lower control arm must be replaced. This is to ensure excessive wear of the ball joint does not occur from the contamination present in the ball joint. - Excessive wear in the ball joint can lead to a separation of the ball joint from the lower control arm. - The procedure below must be carefully followed when replacing the ball joint seal in the event it is damaged while servicing a vehicle. REMOVE 1. Remove lower control arm assembly from vehicle. 2. Wrap a shop towel around the ball joint and seal boot. This is to prevent dirt and cleaning solvent to enter ball joint when cleaning area around ball joint. 3. Using ONLY a solvent such as Mopar Foamy Engine Degreaser or an equivalent, thoroughly clean lower control arm in area around ball joint and seal. Then using a shop towel saturated with the engine degreaser, carefully wipe off the ball joint seal boot. 4. Using 2 screwdrivers remove the ball joint seal retaining ring from the bottom of the ball joint seal. 5. Remove ball joint seal from ball joint. CAUTION: When replacing ball joint seal, do not use any other type of grease to lubricate ball joint other than the lubricant provided in the Mopar Ball Joint Seal service kit, or equivalent. INSTALL 1. Apply grease from the ball joint seal kit, to the specified areas of the ball joint stud and seal. Be sure no grease is present on the seal boot installation section of the seal boot or lower control arm. 2. Slide ball joint seal boot with upper seal ring installed, down tapered section of ball joint stud. Seal boot is to be installed on stud of ball joint until Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5842 seal boot is sitting on seal groove in lower control arm. 3. Carefully position ball joint seal boot in seal retaining groove on lower control arm. After installing seal boot in retaining groove, carefully bleed air out of sealing boot without getting grease pushed into seal boot retaining groove in lower control arm. 4. Place Retaining Ring Installer, Special Tool, 6875-1, or equivalent over ball joint seal boot. Using adjusting knob, adjust tool so bottom edge of tool is even with top of retaining ring groove in seal boot. 5. Place seal boot retaining ring on Installer, Special Tool, 6875-1, or equivalent. Then place expandable collar from Installer, Special Tool, 6875 over tapered cone of the special tool. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5843 6. Using the expandable collar of Installer, Special Tool, 6875, or equivalent push the seal boot retaining ring down the cone of Installer, Special Tool, 6875, or equivalent. 7. Continue pushing retaining ring down Installer, Special Tool, 6875, or equivalent until it is installed in the retaining ring groove of the seal boot. 8. Remove Installer, Special Tool, 6875, or equivalent from the ball joint seal boot. When removing tool from seal boot be careful not to damage the seal boot with the tool. 9. Check retaining ring installation on seal boot to ensure it is fully seated in seal boot groove and the ends are not twisted. Also, make sure upper sealing ring is on seal boot and correctly installed. Check seal boot for damage before installing back on car. 10. Install lower control arm assembly back on vehicle. Upper Ball Joint Replacement GENERAL INFORMATION The ball joints are replaceable ONLY as an assembly, do not attempt any type of repair on the ball joint assembly. The replacement procedure for the ball joint assembly is detailed in this section of the service manual. The ball joint housing is a pressed fit into the control arm with the joint stud retained in the knuckle by a castle nut. The castle nut is retained on the ball joint stud by a cotter pin. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5844 The procedure for the removal and replacement of the rear control arm ball joint must be done with the rear control arm removed from the vehicle. The ball joint will require the use of an arbor press to remove and install it on the control arm. REMOVE 1. Using a screw driver or other suitable tool, pry seal boot up and off of ball joint assembly. 2. Position Receiving Cup, Special Tool 6758, or equivalent to support control arm when removing ball joint assembly. Install Remover/Installer, Special Tool 6804, or equivalent on top of ball joint assembly. 3. Using an arbor press, press the ball joint assembly out of the control arm. INSTALL 1. By hand, position ball joint assembly into ball joint bore of control arm. Be sure ball joint assembly is not cocked in the bore of the control arm, this will cause binding of the ball joint assembly, when being pressed into lower control arm. 2. Position assembly in an arbor press with Receiving Cup, Special Tool 6758, or equivalent supporting lower control arm. Then install Remover/Installer, Special Tool 6804, or equivalent on the top of the ball joint assembly. CAUTION: When installing the ball joint in the upper control arm, do not press the ball joint into the control all the way. The lip on the ball joint Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5845 must not touch the surface of the control arm. Refer to Step 3 below when installing the ball joint. 3. Carefully align all pieces. Using the arbor press, press the ball joint into the control arm until a gap of 3 mm (1/8 inch) is between lip on ball joint and surface of lower control arm. 4. Install a NEW ball joint assembly sealing boot on ball joint assembly. CAUTION: Do not use an arbor press to install the sealing boot on the lower control arm ball joint assembly. Damage to the sealing boot can occur due to excessive pressure applied to sealing boot when being installed. 5. Position Receiving Cup, Special Tool 6758 over sealing boot so it is aligned properly with bottom edge of sealing boot. Apply pressure BY HAND to special tool 6758, or equivalent until sealing boot is pressed squarely against surface of control arm. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5846 Ball Joint: Service and Repair Ball Joint Seal Boot Replacement (Front Suspension) 1. Using a screw driver or other suitable tool, pry seal boot off of the ball joint assembly. 2. Install a NEW ball joint assembly sealing boot on ball joint assembly. Install sealing boot as far as possible on ball joint assembly. CAUTION: Do not use an arbor press to install the sealing boot on the upper control arm ball joint assembly. Damage to the sealing boot can occur do to excessive pressure applied to sealing boot when being installed. 3. Position Receiving Cup, Special Tool 6758, or equivalent over sealing boot so it is aligned properly with bottom edge of sealing boot. Apply pressure BY HAND to special tool 6758, or equivalent until sealing boot is pressed squarely against surface of upper control arm. 4. Properly lubricate the upper ball joint assembly using only Mopar Multi-Mileage Lube or an equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing Control Arm Bushing: Service and Repair Lower Control Arm Front Isolator Bushing NOTE: To perform removal and replacement of the lower control arm isolator bushings, the lower control arm must be removed from the vehicle. DISASSEMBLY 1. Remove lower control arm assembly from vehicle. 2. Install Bushing Remover, Special Tool 6602-5 and Bushing Receiver, Special Tool MB-990799 on Special Tool C-4212-F, or equivalents. 3. Install lower control arm on Special Tools assembled for removal of the front isolator bushing. Be sure Special Tool MB-990799 is square on lower control arm and Special Tool 6602-5, or equivalents is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F, or equivalent to press front bushing out of lower control arm. ASSEMBLY 1. Mount Bushing Installer, Special Tool 6876 on screw portion of Remover/Installer Special Tool C-4212-F, or equivalent. 2. Start front bushing into lower control arm by hand, making sure it is square with its mounting hole in the lower control arm. Bushing is to be installed in lower control arm from the machined surface side of lower control arm bushing hole. 3. Install lower control arm on Special Tools assembled for installation of front isolator bushing into lower control arm. Be sure Special Tool 6758, or equivalent is square on lower control arm and Special Tool 6876 is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Specials Tool C-4212-F, or equivalent pressing front bushing into lower control arm. Continue pressing front bushing into lower control arm until bushing is sitting flush on the machined surface of the lower control arm. This will correctly position front bushing in lower control arm. 5. Install lower control arm assembly back on vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5852 Control Arm Bushing: Service and Repair Lower Control Arm Rear Isolator Bushing NOTE: To perform removal and replacement of the lower control arm isolator bushings, the lower control arm must be removed from the vehicle. DISASSEMBLY 1. Remove lower control arm assembly from vehicle. 2. Install Bushing Remover, Special Tool 6756 and Bushing Receiver, Special Tool C-4366-2 on Special Tool C-4212-F, or equivalents. 3. Install Special Tools assembled for removal of the rear isolator bushing on the lower control arm. Be sure Special Tool C-4366-2 is square on lower control arm and Special Tool 6756, or equivalents is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F, or equivalent to press rear bushing out of lower control arm. ASSEMBLY 1. Start rear bushing into lower control arm by hand, making sure it is square with its mounting hole in the lower control arm. Bushing is to be installed from the machined surface side of lower control arm bushing hole, with the void in rubber portion of bushing facing away from ball joint. 2. Mount Bushing Installer, Special Tool 6760 on screw portion of Remover/Installer Special Tool C-4212-F, or equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5853 3. Install Special Tools assembled for installation of rear isolator bushing into lower control arm on the lower control arm. Be sure Special Tool 6756 is square on lower control arm and Special Tool 6760, or equivalents is positioned correctly on isolator bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F, or equivalents pressing rear bushing into lower control arm. Continue pressing rear bushing into lower control arm until bushing is sitting flush on the machined surface of the lower control arm. This will correctly position rear bushing in lower control arm. 5. Install lower control arm assembly back on vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5854 Control Arm Bushing: Service and Repair Control Arm Clevis Bushing NOTE: To perform removal and replacement of the lower control arm clevis bushing, the lower control arm must be removed from the vehicle. DISASSEMBLE 1. Remove lower control arm assembly from vehicle. 2. Install Bushing Remover, Special Tool 6877 and Bushing Receiver, Special Tool 6876 on Special Tool C-4212-F, or equivalents. 3. Install lower control arm on Special Tools assembled for removal of the clevis isolator bushing. Be sure Special Tool 6876 is square on lower control arm and Special Tool 6877, or equivalents is positioned correctly on clevis bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F, or equivalent to press clevis bushing out of lower control arm. ASSEMBLE 1. Start clevis bushing into lower control arm by hand, making sure it is square with its mounting hole in the lower control arm. Bushing is to be installed in lower control arm from the machined surface side of lower control arm bushing hole. 2. Mount Bushing Installer, Special Tool 6877 on screw portion of Remover/Installer Special Tool C-4212-F, or equivalents. 3. Install Special Tools assembled for installing clevis bushing into lower control arm lower, on the lower control arm and clevis bushing. Be sure Special Tool 6876 is square on lower control arm and Special Tool 6877, or equivalents is positioned correctly on bushing. 4. Tighten screw on Remover/Installer Special Tool C-4212-F, or equivalent pressing clevis bushing into lower control arm. Continue pressing clevis bushing into lower control arm until bushing is sitting flush with the machined surface of the lower control arm. This will correctly position rear bushing in lower control arm. 5. Install lower control arm assembly back on vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications Cross-Member: Specifications FRONT: To Body Mounting Bolts ...................................................................................................................... ............................................ 163 Nm (120 ft. lbs.) REAR: To Body Attaching Bolts ...................................................................................................................... ................................................ 95 Nm (70 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications > Page 5858 Cross-Member: Description and Operation This vehicle is equipped with a bolt in type rear suspension crossmember. The crossmember on this vehicle is the same for all of the optional suspensions that are available on the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal Cross-Member: Service and Repair Removal 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove both rear wheel and tire assemblies from the vehicle. Fig. 5 3. Remove the shock absorber clevis bracket to rear knuckle attaching bolt and nut on both sides of the vehicle. 4. Remove muffler support Bracket from rear frame rail. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5861 5. Remove the rear exhaust pipe hanger from the rear suspension crossmember. Let exhaust system drop down as far as possible. 6. Position a transmission jack and wooden block under the center of the rear suspension crossmember to support and lower crossmember during removal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5862 Fig. 7 7. If vehicle is equipped with antilock brakes, remove routing clips for wheel speed sensor cable from brackets on upper control arm. 8. Remove the nuts and bolts on each side of vehicle attaching the 4 lateral links to the knuckles. 9. Remove the 4 bolts attaching the rear suspension crossmember to rear frame rails. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5863 10. Lower the rear suspension crossmember enough to access the upper control arm pivot bar to crossmember attaching bolts. Remove the 4 bolts attaching the upper control arms to the suspension crossmember. Remove the control arms from the crossmember. 11. Lower the rear suspension crossmember, lateral arms and stabilizer bar as far as possible using the transmission jack. Then with the aid of a helper remove rear suspension crossmember from the vehicle. 12. Transfer the lateral arms, stabilizer bar mounting brackets and the stabilizer bar and bushings to the replacement crossmember before installing the replacement crossmember in the vehicle. Tighten the stabilizer bar mounting bracket to rear crossmember mounting bolts to a torque of 27 Nm (20 ft. lbs.). Tighten the 4 lateral arm to crossmember attaching bolts to a torque of 95 Nm (80 ft. lbs.). Install the lateral arm to crossmember bolts so head of bolt will be toward the front of the vehicle when the crossmember is installed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5864 Cross-Member: Service and Repair Installation 1. Install the rear suspension crossmember, lateral arms and rear stabilizer bar back into the vehicle as an assembly. 2. With the aid of a helper position rear suspension crossmember back in vehicle and support it using the transmission jack. 3. Align the upper control arm pivot bars with the mounting holes in the rear suspension crossmember. Install and tighten the 4 pivot bar to crossmember attaching bolts to a torque of 107 Nm (80 ft. lbs.). 4. Using transmission jack, raise rear suspension crossmember up to the rear frame rails and loosely install the 4 attaching bolts. 5. Position a drift of the appropriate size into the positioning hole in each side of rear suspension crossmember and locating holes in the frame rail of the body. This is required to properly position rear suspension crossmember side-to-side and front to rear in the body of the vehicle. Then tighten the 4 crossmember to frame rail attaching bolts to 95 Nm (70 ft. lbs.). Remove drifts from rear suspension crossmember. 6. Align lateral links with knuckles and install the lateral arm to knuckle attaching bolts. Tighten the 4 lateral arm to spindle attaching bolts to a torque of 95 Nm (70 ft. lbs.). 7. Remove transmission jack supporting rear suspension crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5865 8. Install muffler support bracket on rear frame rail. Install rear exhaust pipe hanger on rear suspension crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5866 Fig. 7 9. If vehicle is equipped with antilock brakes, install the wheel speed sensor cable routing clip on upper control arm mounting bracket. Install and securely tighten attaching bolt. 10. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 11. Lower vehicle to the ground. 12. Check and reset if required, rear wheel alignment to meet the preferred specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service Precautions Front Steering Knuckle: Service Precautions CAUTION: The front suspension steering knuckle is not a repairable component of the front suspension. IT MUST BE REPLACED IF FOUND TO BE DAMAGED IN ANY WAY. If it is determined that the steering knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the steering knuckle. NOTE: On this vehicle the steering knuckle must be removed from the vehicle when servicing the front hub bearing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service Precautions > Page 5870 Front Steering Knuckle: Description and Operation The steering knuckle is a single casting with legs machined for attachment to the vehicle's upper and lower control arm ball joints. The steering knuckle also has machined abutments on the casting to support and align the front brake caliper assembly. The knuckle also holds the front drive shaft outer C/V joint hub and bearing assembly. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. The outer C/V joint is retained to the hub and bearing assembly using a nut, nut lock and cotter pin. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal 1. Remove cotter pin, nut lock, and spring washer from the front stub axle. CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 2. Loosen hub nut while 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 on jack stands or centered on a frame contact type hoist. 4. Remove front tire and wheel assembly from the hub. 5. Remove front disc brake caliper to steering knuckle guide pin attaching bolts. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5873 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. 7. Support brake caliper/adapter assembly using a wire hook and not by hydraulic hose. 8. Remove the braking disc from the front hub/bearing assembly. 9. If vehicle is equipped with 15 inch wheels, remove lower ball joint heat shield from lower control arm. Heat shield must be removed before attempting to separating ball joint stud from steering knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5874 10. Remove nut attaching outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. 11. Remove the tie rod end from steering knuckle arm, using Remover, Special Tool MB-991113, or equivalent. 12. If equipped with antilock brakes remove the speed sensor cable routing bracket from the steering knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5875 13. Remove cotter pin and castle nut from stud of lower ball joint at the steering knuckle. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in step Step 14 below. 14. Turn steering knuckle so the front of the steering knuckle is facing as far outboard-in the wheel well as possible. Using a hammer strike the boss on the steering knuckle, until steering knuckle separates from stud of lower ball joint. When striking steering knuckle care MUST be taken not to hit lower control arm or ball joint grease seal. CAUTION: Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C/V joint. Refer to Transmission and Drivetrain. 15. Lift up on steering knuckle separating it from the lower ball joint stud. Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5876 16. Separate the steering knuckle from the outer C/V joint. Separate steering knuckle from outer C/V joint, by supporting the driveshaft while pulling steering knuckle away from the outer C/V joint. 17. Remove the cotter pin and nut from the upper ball joint stud to steering knuckle attachment. 18. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C-3894-A, or equivalent. 19. Remove steering knuckle from vehicle. 20. The bolt in type front wheel bearing used on the vehicle is transferable to the replacement steering knuckle if bearing is found to be in usable condition. Refer to Transmission and Drivetrain for proper wheel bearing removal and installation procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5877 Front Steering Knuckle: Service and Repair Installation 1. If required install a hub/bearing assembly into the steering knuckle before installing steering knuckle on vehicle. Refer to Transmission and Drivetrain for proper wheel bearing removal and installation procedure. 2. Slide drive shaft back into front hub/bearing assembly. Then install steering knuckle onto the ball joint stud in lower control arm. 3. Install the steering knuckle to lower ball joint stud castle nut. 4. Install upper ball joint in steering knuckle. Install the steering knuckle to upper ball joint nut. Tighten the upper ball joint castle nut to a torque of 62 Nm (45 ft. lbs.). Then, using a crowfoot and torque wrench, tighten the lower ball joint nut to a torque of 75 Nm (55 ft. lbs.). Install cotter pins in upper and lower ball joint studs. 5. If equipped with antilock brakes install the speed sensor cable routing bracket on the steering knuckle and securely tighten the attaching bolt. CAUTION: When installing tie rod on steering knuckle the heat shield must be installed. If heat shield is not installed, tie rod seal boot can fail due to excessive heat from brake rotor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5878 6. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket tighten the attaching nut to a torque of 61 Nm (45 ft. lbs.). CAUTION: The ball joint seal boot heat shield must be installed. If heat shield is not installed, ball joint seal boot can fail due to excessive heat from brake rotor. 7. Install the lower ball joint heat shield on the steering knuckle. 8. Install braking disc back on hub and bearing assembly. 9. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 10. Install disc brake caliper assembly to steering knuckle guide pin bolts. Tighten caliper assembly guide pin bolts to a torque of 31 Nm (23 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5879 11. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install washer and hub nut onto stub axle and tighten nut. 12. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 203 Nm (150 ft. lbs.) of torque. 13. Install the spring washer, hub nut lock, and new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock. 14. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Then tighten to a torque of 129 Nm (95 ft. lbs.). 15. Lower vehicle. 16. Set front Toe on vehicle to required Alignment specification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications Lateral Stabilizer Rod: Specifications To Knuckle Bolts/Nuts ......................................................................................................................... .................................................... 95 Nm (70 ft. lbs.) Jam Nuts ........................................................... ........................................................................................................................................ 65 Nm (48 ft. lbs.) To Suspension Crossmember Bolts .......................................................................................................................................................... 95 Nm (70 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 5883 Lateral Stabilizer Rod: Service Precautions CAUTION: Do not attempt to straighten or repair a lateral link. Do not apply heat to the lateral link adjusting screws or to the jam nuts, when loosening or adjusting the lateral links NOTE: The rear suspension lateral links are only serviced as complete assemblies. The isolator bushings used in the lateral links are not serviced as separate components. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 5884 Lateral Stabilizer Rod: Testing and Inspection Inspect the lateral link isolator bushings and sleeves for signs of damage or deterioration. If the lateral link isolator bushings or sleeves are damaged or are deteriorated, replacement of the lateral link assembly will be required. The isolator bushings are not serviceable as a separate component of the lateral link assembly. Inspect the lateral links for signs of contact with the ground or road debris which has bent or caused other damage to the lateral link. If the lateral link is bent or damaged, the lateral link will require replacement. Do not attempt to repair or straighten a lateral link. CAUTION: Do not apply heat to the lateral link adjusting screws or to the jam nuts, when loosening or adjusting the lateral links. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Forward Lateral Link Replacement Lateral Stabilizer Rod: Service and Repair Forward Lateral Link Replacement REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the side of the vehicle requiring lateral link removal. 3. Remove the rear stabilizer bar attaching link from the forward lateral link. 4. Remove the nut, bolt and washer attaching the forward lateral link to the knuckle. 5. Remove nut, bolt and washer, attaching the lateral link to the rear suspension crossmember. 6. Remove the forward lateral link from the vehicle. INSTALL 1. Install the lateral link and the attaching nut and bolt at rear suspension crossmember. The forward lateral link is to be installed with the cup in cast portion facing down and toward rear knuckle. 2. Install the lateral link and attaching nut and bolt at rear knuckle. 3. Torque both lateral link attaching bolts to 95 Nm (70 ft. lbs.). 4. Install the rear stabilizer bar attaching link, isolator bushings and attaching nut on the forward lateral link. Securely tighten the attaching nut. 5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 6. Lower vehicle to the ground. 7. Check and reset rear wheel Camber and Toe to specifications if required. Refer to Alignment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Forward Lateral Link Replacement > Page 5887 Lateral Stabilizer Rod: Service and Repair Rear Link REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the side of the vehicle requiring lateral link removal. 3. Remove the nut, bolt and washer attaching the lateral link to the knuckle. 4. Remove the bolt and nut attaching the lateral link to the rear suspension crossmember. 5. Remove rear lateral link from vehicle. INSTALL 1. Install the lateral link and the attaching nut and bolt at rear suspension crossmember. The rear lateral link is to be installed with the adjusting screw toward rear knuckle not rear suspension crossmember. 2. Install the lateral link and the attaching bolt nut and washer at rear knuckle. 3. Torque both lateral link attaching bolts to 95 Nm (70 ft. lbs.). 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 5. Lower vehicle to the ground. 6. Check and reset rear wheel Camber and Toe to specifications if required. Refer to Alignment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Description and Operation Rear Knuckle: Description and Operation A cast iron rear knuckle is attached to the upper control arm by the upper ball joint and to the rear shock absorber assembly. The lateral movement of the rear knuckle is controlled using two lateral arms attached to the bottom of the knuckle and by the upper control arm attached to the top of the knuckle. The outboard ends of the two lateral arms are mounted forward and rearward of the knuckle centerline, and the inboard ends are mounted to the rear suspension crossmember. Fore and aft movement of the knuckle is controlled by the trailing link. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal Rear Knuckle: Service and Repair Removal NOTE: The rear suspension knuckle is not a repairable component of the rear suspension. If it is determined that the knuckle is broken or bent when servicing the vehicle, no attempt is to be made to repair or to straighten the knuckle. The knuckle must be replaced if found to be damaged in any way. PROCEDURE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly from the vehicle. 3. Remove rear brake drum from rear hub and bearing assembly. Fig. 7 4. If vehicle is equipped with antilock brakes remove the rear wheel speed sensor from the brake support plate and brake flex hose routing bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5893 5. Remove the park brake cable from the park brake actuating lever. Then remove the park brake cable from the rear brake support plate. Park brake cable is removed from brake support plate using this procedure. Position a 1/2 inch box end wrench over cable retainer to collapse retaining tabs. Then pull bear brake cable from brake support plate. 6. Remove the rear hub/bearing assembly retaining nut. Then remove the washer and the hub/bearing assembly from the knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5894 7. Remove the 4 bolts attaching rear brake support plate to knuckle. Then remove brake support plate, brake shoes and wheel cylinder as an assembly from rear knuckle. It is not necessary to remove brake flex hose from wheel cylinder when removing support plate. Brake support plate when removed, must be supported using mechanics wire as shown. 8. Remove the nuts and bolts attaching the forward and rear lateral links to the rear knuckle. 9. Remove cotter pin and castle nut attaching upper control arm ball joint to knuckle. Fig. 14 10. Remove ball joint stud from knuckle using Puller, Special Tool, CT-1106, or equivalent. When using puller, install castle nut on ball joint stud to protect threads from damage. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5895 11. Remove the nut and washer attaching the trailing link to the rear knuckle. Use a wrench on the flat of the trailing link to keep it from turning when removing nut. 12. Remove the shock absorber clevis bracket to knuckle attaching nut and bolt. 13. Remove the knuckle assembly from the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5896 Rear Knuckle: Service and Repair Installation NOTE: The rear suspension knuckle is not a repairable component of the rear suspension. If it is determined that the knuckle is broken or bent when servicing the vehicle, no attempt is to be made to repair or to straighten the knuckle. The knuckle must be replaced if found to be damaged in any way. PROCEDURE 1. Install knuckle on clevis bracket of rear shock absorber. Then install clevis bracket to shock absorber attaching bolt with head of bolt facing rear of vehicle. CAUTION: The inner and outer bushing location on the trailing link to rear knuckle attachment is important. Do not interchange the inner and outer bushing location when installing knuckle back on trailing link. Also, when installing trailing link bushing retainers, retainers must be installed with cupped side of retainer facing away from bushing and knuckle. 2. Install knuckle on trailing link. Then install the outer trailing link bushing, bushing retainer and retaining nut on trailing link. Using a large adjustable wrench, to keep trailing link from rotating securely tighten the trailing link retaining nut to a torque of 95 Nm (70 ft. lbs.). 3. Install upper ball joint stud in knuckle. Install and tighten the ball joint stud castle nut to a torque of 67 Nm (50 ft. lbs.). Install cotter pin in ball joint stud. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5897 4. Install the front and rear lateral links and attaching nuts and bolts on the knuckle, Tighten the lateral links to knuckle attaching bolts and nuts to 95 Nm (70 ft. lbs.). 5. Install rear brake support plate assembly onto the knuckle. Install the 4 bolts attaching rear brake support plate to rear knuckle. Tighten the attaching bolts to a torque of 61 Nm (45 ft. lbs.). 6. If vehicle is equipped with ABS brakes, install speed sensor head into rear brake support plate. Torque speed sensor head mounting bolt to 7 Nm (60 inch lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5898 Fig. 7 7. Attach routing bracket for speed sensor cable to brake flex hose bracket and securely tighten attaching bolt. 8. Install park brake cable into brake support plate. Ensure cable retainer is securely holding cable to support plate. Then connect park brake cable to park brake lever on brake shoe. 9. Install rear hub and bearing assembly on knuckle and install hub and bearing assembly retaining nut. Tighten retaining nut to a torque of 250 Nm (185 ft. lbs). 10. Install the brake drum on the hub/bearing assembly. 11. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in Proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 12. Lower vehicle. 13. Check and reset rear wheel alignment to specifications if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications Stabilizer Bushing: Specifications FRONT: Clamp Bolts ......................................................................................................................................... ................................................. 55 Nm (40 ft. lbs.) REAR: Isolator Bushing Retainer Bolt ............................................................................................................................................................. 28 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications > Page 5903 Stabilizer Bushing: Service and Repair REPLACEMENT 1. Bend back the 4 crimp locations on the stabilizer bar bushing retainer. 2. Separate the stabilizer bar bushing retainer. 3. Stabilizer bar bushings are removed by opening slit and peeling bushing off stabilizer bar. 4. Install new stabilizer bar bushings on the stabilizer bar. Bushings must be installed on sway bar with slit in bushing facing front of vehicle when sway bar is installed. 5. Install bushing retainers back on stabilizer bar bushings. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Mounting Nuts ..................................................................................................................................... ................................................... 105 Nm (78 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 5907 Stabilizer Link: Testing and Inspection Inspect the bushings and sleeves in the stabilizer bar attaching links for damage or deterioration. Inspect the stabilizer bar attaching link to ensure it is not bent or broken. If any of these conditions are present when inspecting the attaching links, replacement of the attaching link is required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Front Suspension Spring ( Coil / Leaf ): Description and Operation Front Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. During service procedures when both springs are removed, mark springs to ensure installation in original position. If the coil springs require replacement, be sure that the springs needing replacement, are replaced with springs meeting the correct load rating and spring rate for the vehicle and its specific options. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Front > Page 5912 Suspension Spring ( Coil / Leaf ): Description and Operation Rear Rear coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. During service procedures when both rear coil springs are removed, mark the coil springs to ensure installation of the springs in their original position. NOTE: If coil springs require replacement, be sure the springs needing replacement, are replaced with springs meeting the correct load rating for the vehicle and its specific options. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Page 5913 Suspension Spring ( Coil / Leaf ): Service and Repair Coil springs are rated separately for each side of vehicle depending on optional equipment and type of service. During service procedures where both springs are removed, mark springs (Chalk, Tape, etc.) to ensure installation in original position. If the coils springs require replacement, be sure-that the springs being replaced, are replaced with springs meeting the correct load and spring rate for the vehicle. NOTE: During service procedures requiring removal or installation of a coil spring, be sure that the first full top and bottom coil of the spring is captured by the jaws of spring compressor. Replacement of the coil spring requires removal of the shock absorber from the vehicle, and the disassembly of the shock absorber. Refer to shock absorber for the required removal and replacement and overhaul procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications FRONT: To Clevis Pinch Bolt ............................................................................................................................ ................................................ 95 Nm (70 ft. lbs.) To Shock Tower Bolts ........................................... ............................................................................................................................... 90 Nm (68 ft. lbs.) Clevis To Control Arm Bolt .................................................................................................................. ............................................... 90 Nm (68 ft. lbs.) Rod To Upper Mount Nut ....................................... ............................................................................................................................. 54 Nm (40 ft. lbs.) REAR: Mounting Bracket To Body .................................................................................................................. ................................................ 54 Nm (40 ft. lbs.) To Suspension Knuckle Bolt/Nut ......................................................................................................................................................... 95 Nm (70 ft. lbs.) Rod To Upper Mount Nut ............................................................................................ ........................................................................ 54 Nm (40 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front The front shock absorber and suspension of the vehicle is supported by coil springs positioned around the shock absorbers. The springs are contained between an upper seat, located just below the top shock absorber mounting bracket and a lower spring seat located on the shock absorber. The top of each shock absorber assembly is bolted to the cast aluminum upper control arm bracket which is then bolted to the shock tower of the vehicle using 4 mounting bolts. The bottom of the shock absorber assembly attaches to the lower control arm of the vehicle using a thru-bolt and prevailing torque nut. Caster and camber is a fixed setting (net build) on all vehicles and is not required nor can be adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5919 Suspension Strut / Shock Absorber: Description and Operation Rear The rear shock absorber assemblies support the weight of the vehicle using coil springs positioned around the shock absorbers. The coil springs are contained between the upper mount of the shock absorber and a lower spring seat on the body of the shock absorber. The top of each shock absorber assembly is bolted to the top of the inner fender through a rubber isolated mount. The bottom of the shock absorber assembly attaches to the rear knuckle using a thru-bolt. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut / Shock Absorber: Testing and Inspection Front 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged shock absorber dust boots. 3. Lift the dust boot and inspect the shock absorber for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the shock absorber rod and the seal is not unusual and does not affect performance of the shock absorber. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 5922 Suspension Strut / Shock Absorber: Testing and Inspection Rear 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged shock absorber dust boots. 3. Inspect for damaged lower spring isolator. 4. Lift the dust boot and inspect the shock absorber for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the shock absorber rod and the seal is not unusual and does not affect performance of the shock absorber. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Front WARNING: Do not remove shock rod nut while shock assembly is installed in vehicle, or before shock assembly spring is compressed. REMOVE 1. Loosen wheel nuts. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove wheel and tire assembly from location on front of vehicle requiring strut removal. 4. If both shock absorbers are removed, mark the shock absorbers right and left according to which side of the vehicle they were removed from. Fig. 6 5. Remove the wheel speed sensor cable routing bracket from the steering knuckle. Fig. 7 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5925 6. Remove the cotter pin and castle nut from the upper ball joint stud. 7. Remove the upper ball joint stud from the steering knuckle using Puller, Special Tool, C-3894-A, or equivalent. Pull steering knuckle outward and position toward the rear of the front wheel opening. 8. Remove pinch bolt attaching shock absorber clevis to shock absorber. Fig. 10 9. Remove the thru-bolt attaching the shock absorber clevis to the lower control arm. 10. Remove the clevis from the shock absorber by carefully tapping the clevis off the shock absorber using a soft (brass) drift. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5926 11. Remove the 4 bolts attaching the shock absorber/upper control arm mounting bracket to the shock tower of the vehicle. 12. Remove the shock absorber and upper control arm mounting bracket as an assembly from the vehicle. The shock absorber is removed out through the front area of the front wheel well. INSTALL 1. Install the shock absorber assembly, with the clevis removed, into shock tower. Aligning the 2 locating pins and the 4 mounting holes, on the upper control arm shock absorber mount with the 4 holes in shock tower. Install the 4 upper control arm mount to shock tower mounting bolts. Tighten the 4 bolts to a torque of 90 Nm (68 ft. lbs.). 2. Install the clevis on the shock absorber. Clevis is installed by tapping it onto the fluid reservoir of the shock absorber using a soft (brass) drift until fully seated against locating tab on shock absorber. Orientation tab on locating tab must be positioned in the split of the clevis. 3. Install the clevis bracket to lower control arm thru-bolt. Do not tighten or torque the thru-bolt at this time. 4. Install upper ball joint into steering knuckle. Install castle nut on ball joint stud. Tighten castle nut to a torque of 62 Nm (45 ft. lbs.). Install cotter pin in stud of ball joint. 5. Install the routing bracket for the speed control cable on the steering knuckle. Install and securely tighten the routing bracket attaching bolt. CAUTION: When supporting lower control arm with jack stand, do not position jack stand under the ball joint cap on the lower control arm. Position in area of lower control arm shown. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5927 Fig. 13 6. Lower vehicle to the ground with a jack stand positioned under the lower control arm. Continue to lower vehicle so the total weight of the vehicle is supported by the jack stand and lower control arm. 7. Tighten the shock absorber clevis to lower control arm bushing thru-bolt to a torque of 95 Nm (70 ft. lbs.). 8. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). Rear NOTE: Access for the bolts attaching the rear shock absorber upper mount is from inside the trunk. REMOVE 1. Roll back carpeting on top of rear shock tower to access shock mounting bolts. 2. Remove plastic cover from the top of the shock tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5928 3. Remove the 2 nuts attaching the shock absorber upper mount/spring seat to the shock tower. 4. Raise vehicle on jackstands or centered on a frame contact type hoist. 6. Remove the rear wheel and tire assembly from the vehicle. 6. Remove bolt attaching shock absorber to rear knuckle. 7. Remove the shock absorber from the rear knuckle first, when removing the shock absorber from vehicle by pushing down on the rear suspension. 8. Move shock absorber downward and tilt top of shock outward. Then remove shock absorber from vehicle through top of wheel opening. INSTALL 1. Install shock absorber back in vehicle using the reverse sequence of removal. 2. Install upper shock absorber mount into the mounting holes in rear shock tower. 3. Push down on rear knuckle to obtain clearance and then install shock absorber clevis bracket on rear knuckle. 4. Align clevis bracket on shock absorber with bushing in knuckle. Install and tighten bolt to a torque of 95 Nm (70 ft. lbs.). 5. Lower vehicle far enough to gain access to the trunk. 6. Install and tighten the 2 shock absorber mounting bracket attaching nuts to a torque of 54 Nm (40 ft. lbs.). 7. Install plastic cover on shock tower. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5929 8. Install carpeting back on shock tower. 9. Install wheel and tire assembly on vehicle. Then torque all wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat tightening sequence to full specified torque of 129 Nm (95 ft. lbs.). 10. Lower vehicle to the ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5930 Suspension Strut / Shock Absorber: Service and Repair Overhaul Disassembly CAUTION: Do not clamp the shock absorber in a vise by the body of the shock absorber. The clevis bracket must be reinstalled on the shock absorber and clamped in the vise using the clevis bracket. 1. Install clevis bracket back on shock absorber and tighten pinch bolt. Then using the clevis bracket, clamp the shock absorber assembly in vise, with shock absorber in a vertical position. 2. Mark coil spring and shock absorber assembly right or left, according to which side of the vehicle the shock absorber was removed from, and which shock absorber the coil spring was removed from. WARNINGS: Do not remove the shock absorber rod nut, before shock absorber coil spring is compressed, removing spring tension from upper control arm/shock absorber mounting bracket. - When compressing coil spring for removal from shock absorber, the first full top and bottom coil of the coil spring must be captured by the jaws of the coil spring compressor. 3. Compress shock absorber coil spring, using Professional Services Equipment Spring Compressor, GP-2020-C3.5 fitted with the GP-C42 upper spring shoe and GP-A20 lower spring shoe, or equivalents. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5931 4. Hold the rod of the shock absorber from rotating using Shock Absorber Socket, Snap-On A136 or an equivalent. Then remove the shock absorber shaft nut. 5. Remove the washer from the shock absorber rod. 6. Remove the shock absorber/upper control arm mounting bracket from the shock absorber assembly. CAUTION: The top and bottom bushings-for the shock absorber rod are unique to the position which they are installed on the rod. When removing the bushings from the rod, attention must be paid to their location so they will be installed correctly when shock absorber is assembled. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5932 7. Remove the shock absorber rod upper isolator bushing from the shock absorber/upper control arm mounting bracket. 8. Remove the shock absorber rod lower isolator bushing and sleeve, from the shock absorber/upper control arm mounting bracket. Remove upper spring isolator from mounting bracket. 9. Remove the lower isolator bushing from the shock absorber rod sleeve. 10. Remove washer from top of dust shield. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5933 11. Remove the dust shield from the shock absorber assembly. 12. Remove the coil spring and spring compressor as an assembly from the shock absorber assembly. Mark springs, left and right, for installation back on the correct side of the vehicle. 13. Remove the jounce bumper and sleeve, from the rod of the shock absorber assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5934 14. Remove the coil spring isolator from the lower spring seat on the shock absorber assembly. 15. Inspect the shock absorber for any condition of rod binding over the full stroke of the shock rod. 16. Inspect the shock mount and upper spring seat/isolator assembly for the following: - Mount for cracks and distortion and locating studs for any sign of damage. - Severe deterioration of the upper or lower coil spring isolators. - Deterioration of the shock absorber rod to shock absorber mounting bracket bushings. - Inspect dust shield for rips and/or deterioration. - Inspect jounce bumper for cracks and signs of deterioration. 17. Replace any components of the shock absorber assembly found to be worn or defective during the inspection, before re-assembling the shock absorber. Assembly CAUTION: Do not clamp the shock absorber in a vise by the body of the shock absorber. The clevis bracket must be reinstalled on the shock absorber clamped in the vise using the clevis bracket. 1. Install clevis bracket back on replacement shock absorber and tighten pinch bolt. Then using the clevis bracket, clamp the shock absorber assembly in a vise, with shock absorber in a vertical position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5935 2. Install the coil spring isolator on the lower spring seat of the shock absorber assembly. Isolator must be positioned on lower spring seat as shown. 3. Install jounce bumper on rod of shock absorber assembly. 4. Install the sleeve, undercut side facing down, on the rod of the shock absorber assembly. Be sure sleeve is positioned squarely on step of shock absorber rod. WARNING: If a replacement coil spring is to be installed on the strut assembly, the first full top and bottom coil of the spring must be captured by the jaws of the coil spring compressor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5936 5. Install the coil spring (with small diameter coils down) on the shock absorber assembly. Be sure bottom coil of spring is correctly positioned on the lower spring isolator. 6. Install dust shield on rod of shock absorber assembly. 7. Install bottom washer on rod of shock absorber assembly and on top of dust shield. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5937 CAUTION: The top and bottom shock absorber rod bushings are unique to the position which they are installed on the rod. When installing the bushings on the rod, attention must be paid to their location so they are installed correctly. 8. Install the lower isolator bushing and sleeve in the shock absorber/lower control mounting bracket. Install coil spring upper isolator in mounting bracket. 9. Install the upper isolator bushing on the sleeve and the shock absorber/upper control arm mounting bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5938 10. Install the shock absorber/upper control arm mounting bracket on the shock absorber assembly. 11. Install the upper washer on rod of shock absorber and position it over top bushing with the word TOP facing up. WARNING: The following 2 steps must be completely done before spring compressor, GP-2020-C3.5 or an equivalent is released from the coil spring. 12. Install nut on rod of shock absorber assembly. Install Shock Absorber Socket, Snap-On A136 or an equivalent on end of shock rod to keep rod from turning Then tighten rod nut using a crowfoot to a torque of 55 Nm (40 ft. lbs.). 13. Relieve all tension from spring compressor. After all spring tension has been remove from the spring compressor, remove it from the shock absorber assembly. 14. Install shock absorber assembly back in the vehicle. General Information The rear shock is not serviced and must be replaced as an assembly if found to be defective. The shock absorber is available with 2 calibrations, be sure the shock absorber is replaced with an assembly of the same calibration. The components of the shock absorber assembly listed below are replaceable if found to be defective. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5939 - Coil spring (Coil springs come in a standard and high rate be sure spring is replaced with a spring of the correct rate.) - Dust shield - Mount assembly - Jounce Bumper - Lower Spring Isolator - Shaft Nut Disassembly 1. Remove shock absorber assembly requiring service from the vehicle. 2. Position shock absorber assembly in a vise. Shock absorber is to be clamped only by the clevis bracket on the bottom of the shock absorber. 3. Mark coil spring and strut assembly right or left, according to which side of vehicle strut was removed from, and which strut coil spring was removed from. WARNING: Do not remove shock absorber rod nut, before shock absorber coil spring is compressed, removing spring tension from upper control arm/shock absorber mounting bracket. - When compressing coil spring for removal from shock absorber assembly, the first full top and bottom coil of the spring must be captured by the jaws of the coil spring compressor. 4. Compress shock assembly coil spring, using Professional Services Equipment Spring Compressor, GP-2020-C3.5 or an equivalent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5940 5. Hold the rod of the shock absorber from rotating using Shock Absorber Socket, Snap-On A136 or an equivalent. Then remove the shock absorber shaft nut. 6. Remove the washer from the shock absorber mounting bracket. 7. Remove the shock absorber mounting bracket and the isolator bushings as an assembly from the rod of the shock absorber. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5941 8. Remove the isolator from the coil spring. 9. Remove the washer from the top of the dust shield and shock absorber rod. 10. Remove the dust shield from the shock absorber assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5942 11. Remove the coil spring and the spring compressor as an assembly from the shock absorber. Mark left and right springs for installation back on correct side of vehicle. Fig. 47 12. Remove the jounce bumper and the collar from the rod of the shock absorber assembly. 13. Remove the coil spring isolator from the lower spring seat on the shock absorber assembly. 14. Inspect the shock absorber for any condition of shaft binding over full stroke of the rod. 15. Inspect all disassembled components for signs of abnormal wear or failure, replacing any components as required. Inspect shock absorber for signs of abnormal oil leakage and for loss of gas charge. To check for loss of gas charge in shock absorber, push the shaft of the shock absorber in and release, the shaft should return to its fully extended position. If shaft does not return to its fully extended position replace shock absorber. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5943 16. Remove the upper-isolator and the sleeve from the shock absorber mount. 17. Remove the lower isolator from the rear shock absorber mount. 18. Inspect the rear shock absorber mount upper and lower isolators and the upper spring isolator for the following: - Mount for cracks and distortion and locating studs for any sign of damage. - Severe deterioration of the upper or lower coil spring isolators. - Deterioration of the shock absorber rod to shock absorber mounting bracket bushings. - Inspect dust shield for rips and/or deterioration. - Inspect jounce bumper for, cracks and signs of deterioration. Assembly CAUTION: Do not clamp shock absorber in a vise by the body of the shock absorber. The shock absorber must only be clamped in the vise using the clevis bracket on bottom of shock absorber. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5944 1. Install the lower isolator in the, shock absorber mount. Isolator is to be installed with the cupped side of the isolator toward the shock absorber mount. 2. Install the upper isolator and the sleeve in the shock absorber mount. Isolator, and sleeve are to be installed with the tapered side of the isolator facing up. 3. Install the coil spring isolator on the lower spring seat of the shock absorber assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5945 Fig. 51 4. Install the jounce bumper as shown on the rod of the shock absorber assembly. 5. Install the sleeve on the rod of the shock absorber assembly with the undercut side of sleeve facing down. Push sleeve down until seated on the step of the shock absorber rod. WARNING: If a replacement coil spring is to be installed on the strut assembly, the first full top and bottom coil of the spring must be captured by the jaws of the coil spring compressor. 6. Install the coil spring and spring compressor (with small diameter coils down) on the shock absorber assembly. Be sure bottom coil of spring is correctly positioned on the lower spring isolator. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5946 7. Install dust shield on rod of shock absorber assembly. 8. Install washer on rod of shock absorber assembly and on top of dust shield. 9. Install the isolator on the top of the coil spring. Isolator must be installed with the two half circle formations in the isolator facing up. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5947 10. Install the shock absorber mounting bracket and isolators as an assembly on the rod of the shock absorber assembly. 11. Install the top washer on rod of shock absorber and position it over shock absorber mount. Washer must be installed with the word TOP stamped into washer facing up. WARNING: The following 2 steps must be completely done before spring compressor is released from the coil spring. 12. Install nut on rod of shock absorber assembly. Install Shock Absorber Socket, Snap-On A136 or an equivalent on end of shock rod to keep rod from turning. Then tighten rod nut using a crowfoot to a torque of 55 Nm (40 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5948 13. Position shock absorber upper mount on shock absorber, so studs in upper mount are in line with the bolt hole in the shock absorber clevis bracket. 14. Relieve all tension from spring compressor. After all spring tension has been remove from the spring compressor, remove it from the shock absorber assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications Shaft Nuts (Front and Rear) ................................................................................................................ ...................................................... 95 Nm (70 ft. lbs.) Bracket To Body Mounting Bolts ............................................................................................................................................................. 28 Nm (21 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5952 Trailing Arm: Description and Operation The lateral movement of the rear knuckle is controlled by the lateral arms going from the front and rear of the knuckle to the rear suspension crossmember. Fore and aft movement of the knuckle is controlled by a trailing link. The lateral arms and trailing link have rubber isolator bushings at each end to isolate suspension noise from the body of the vehicle. The trailing link bolts to the bottom of the knuckle and to a bracket attached to the floor pan of the vehicle. NOTE: Lateral links, trailing arms and knuckles are normally replaced only when the part has been damaged or when the vehicle has been involved in an accident. If a suspension part has been damaged, be sure to check the underbody dimensions of the car. If the underbody dimensions are not correct, the frame of the vehicle must be straightened, before replacement suspension components are installed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5953 Trailing Arm: Testing and Inspection Inspect the trailing link bushings and retainers for signs of deterioration or damage. If the trailing link bushings are deteriorated or the retainers are damaged, replacement of the trailing link bushings and or the retainers will be required. The bushings and retainers are serviceable as separate components of the trailing link. Inspect the trailing link for signs of contact with the ground or road debris which has bent or caused other damage to the trailing link. If the trailing link is bent or damaged the trailing link will require replacement. Do not ever attempt to repair or straighten a trailing link. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5954 Trailing Arm: Service and Repair REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly from the vehicle. 3. At the knuckle, remove the nut, bushing retainer and outer trailing link bushing from the trailing link. 4. Remove the 4 bolts attaching the trailing link hanger bracket to the floor pan and frame rail. 5. Remove the trailing link and mounting bracket as an assembly from the vehicle. CAUTION: The installation position of the bushings and retainers on the trailing link is important. When separating the trailing link from the hanger bracket, note the position and orientation on the bushings and retainers to ensure they are re-installed correctly. 6. Separate the trailing link from the hanger bracket. To separate trailing link from hanger bracket, use a large adjustable wrench on flat of trailing link to turn link while holding nut stationary. CAUTION: The inner and outer trailing link to hanger bracket bushings and retainers must be installed in their correct position on the trailing link. Do Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5955 not reverse the position of the inner and outer trailing link bushing or retainers on the trailing link. INSTALL 1. Install the inner bushing retainer, and inner bushing on the trailing link. Install the trailing link, retainer and bushing on the hanger bracket. Then install the outer bushing, outer bushing retainer and nut on the trailing link. Tighten the trailing link retaining nut to a torque of 99 Nm (73 ft. lbs.). 2. Install knuckle end of trailing link assembly in rear knuckle. CAUTION: It is important that the following procedure be done when installing the trailing arm hanger bracket to the body of the vehicle. This procedure will ensure that the hanger bracket is installed in the correct position on the vehicle. 3. Install trailing link hanger bracket on vehicle and loosely install the 4 attaching bolts. Then install 2 drift pins of appropriate size in positioning holes on hanger bracket and into locating holes in body. With hanger bracket correctly positioned on vehicle tighten the 4 hanger bracket mounting bolts. CAUTION: When installing trailing link bushing retainers, retainers must be installed with cupped side of retainer facing away from bushing and knuckle. 4. Install the outer lateral link bushing, outer bushing retainer and retaining nut on trailing link. Using a large adjustable wrench on flat of trailing link to keep it from rotating tighten the trailing link retaining nut to a torque of 95 Nm (70 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Tighten front axle shaft stub to ...................................................................................................................... 203 Nm (150 ft. lbs) to 244 Nm (180 ft. lbs.) Tighten Rear Hub/Bearing Assembly Retaining Nut ............................................................................................................................ 250 Nm (185 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 5960 Wheel Bearing: Fluid Type Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5961 Wheel Bearing: Description and Operation All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. However, if servicing of a rear wheel bearing is required, refer to procedures in Testing and Inspection and Service and Repair for the inspection and replacement of the rear wheel bearing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5962 Wheel Bearing: Testing and Inspection The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5963 Wheel Bearing: Service and Repair REMOVE 1. Raise vehicle on jackstands or center on a frame contact type hoist. 2. Remove rear wheel and tire assembly. Rear Brake Drum Removal 3. Remove brake drum from rear hub/ bearing assembly. Rear Hub/Bearing Dust Cap 4. Remove dust cap from rear hub/bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5964 5. Remove hub/bearing assembly to rear spindle retaining nut. 6. Remove rear hub/bearing assembly from spindle. Hub/bearing is removed by pulling it straight off the spindle by hand. INSTALL 1. Install the hub/bearing assembly on the knuckle. Then install a NEW rear hub/bearing assembly retaining nut. Tighten the hub/ bearing assembly retaining nut to a torque of 250 Nm (185 ft. lbs.). 2. Install hub/bearing assembly dust cap, using a soft faced hammer. 3. Install brake drum on rear hub/bearing assembly. 4. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in criss cross pattern to one-half the specified torque. Then repeat pattern, fully tightening the stud nuts to a torque of 109 - 150 Nm (80 - 110 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Tightening 1995-96 Stratus/Cirrus/Breeze .............................................................................................................................................244 Nm (180 ft. lbs.) Tightening 1997 Stratus/Cirrus/Breeze ........................................................................................................... 203 Nm (150 ft. lbs.) to 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for complete details. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5978 Wheels: Specifications Lug Nuts .............................................................................................................................................. ................................. 115 - 155 Nm (85 - 115 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5979 Wheels: Description and Operation Fig. 1 Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use steel or cast aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment equipment. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser Duality or of a substitute design. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. CAUTION: Installing wheels without good metal-to-metal contact could cause loosening of wheel lug nuts. This could adversely affect the safety and handling of your vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information Wheels: Testing and Inspection General Information Wheels must be replaced if they: - Have excessive run out - Are bent or dented - Leak air - Have damaged wheel lug holes Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original equipment replacement wheels are available through the dealer. When obtaining replacement wheels from any other source, they must be equivalent in load carrying capacity. The wheel features (diameter, width, offset, brake clearance, and mounting configuration) must match the original equipment wheels. CAUTION: Failure to use original equipment replacement wheels may adversely affect the safety and handling of your vehicle. CAUTION: Replacement with used wheels is not recommended. The service history of the rim may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 5982 Wheels: Testing and Inspection Tire and Wheel Runout GENERAL INFORMATION Radial run out is the vertical distance between the high and low Print no the tire or wheel edge. Lateral run out is the horizontal movement of the tire or wheel. Radial run out of more than 0.762 mm (0.030 inch) measured at the center line of the tread may cause the vehicle to shake. Lateral run out of more than 0.762 mm (0.030 inch) measured near the shoulder of the tire may cause the vehicle to shake. Runout should always be measured off the vehicle and on a suitable balance machine. Usually radial run out can be reduced by relocating the wheel and tire on the wheel studs (See Method 1). If this does not reduce run out to an acceptable level, the tire can be rotated on the wheel. (See Method 2). Method 1 (Relocate Wheel On Hub) Check accuracy of the wheel mounting surface; adjust wheel bearings. - Drive vehicle a short distance to eliminate tire flat spotting from a parked position. Fig. 2 - Verify all wheel nuts are properly torqued. Fig. 3 - Use run out gauge D-128-TR, or equivalent to determine run out. - Relocate wheel on the mounting, two studs over from the original position. - Retighten wheel nuts until all are properly torqued. This will prevent brake distortion. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 5983 - Check radial run out. If still excessive, mark tire sidewall, wheel, and stud at point of maximum run out and proceed to Method 2. Method 2 (Relocate Tire On Wheel) Rotating tire on wheel is particularly effective when there is run out in both tire and wheel. - Remove tire from wheel and remount wheel on hub in former position. Fig. 5 - Check wheel radial run out. It should be no more than 0.762 mm (0.030 inch). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 5984 Fig. 6 - Lateral run-out should be no more than 0.762 mm (0.030 inch). - If point of the most wheel radial run out is near original chalk mark, remount tire 45 degrees from its original spot. Recheck run out. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 5985 Wheels: Service and Repair Lug Nut Tightening Sequence To install the wheel and tire assembly, first position it properly on the mounting surface using the hub pilot as a guide. Then progressively tighten the lug nuts in the proper sequence to half of the required torque. Finally tighten the lug nuts in the proper sequence to 115 - 155 Nm (85 - 115 ft. lbs.). Never use oil or grease on studs or nuts. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Tighten front axle shaft stub to ...................................................................................................................... 203 Nm (150 ft. lbs) to 244 Nm (180 ft. lbs.) Tighten Rear Hub/Bearing Assembly Retaining Nut ............................................................................................................................ 250 Nm (185 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 5990 Wheel Bearing: Fluid Type Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5991 Wheel Bearing: Description and Operation All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. However, if servicing of a rear wheel bearing is required, refer to procedures in Testing and Inspection and Service and Repair for the inspection and replacement of the rear wheel bearing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5992 Wheel Bearing: Testing and Inspection The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5993 Wheel Bearing: Service and Repair REMOVE 1. Raise vehicle on jackstands or center on a frame contact type hoist. 2. Remove rear wheel and tire assembly. Rear Brake Drum Removal 3. Remove brake drum from rear hub/ bearing assembly. Rear Hub/Bearing Dust Cap 4. Remove dust cap from rear hub/bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5994 5. Remove hub/bearing assembly to rear spindle retaining nut. 6. Remove rear hub/bearing assembly from spindle. Hub/bearing is removed by pulling it straight off the spindle by hand. INSTALL 1. Install the hub/bearing assembly on the knuckle. Then install a NEW rear hub/bearing assembly retaining nut. Tighten the hub/ bearing assembly retaining nut to a torque of 250 Nm (185 ft. lbs.). 2. Install hub/bearing assembly dust cap, using a soft faced hammer. 3. Install brake drum on rear hub/bearing assembly. 4. Install rear wheel and tire assembly on vehicle. Tighten all wheel stud nuts in criss cross pattern to one-half the specified torque. Then repeat pattern, fully tightening the stud nuts to a torque of 109 - 150 Nm (80 - 110 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Tightening 1995-96 Stratus/Cirrus/Breeze .............................................................................................................................................244 Nm (180 ft. lbs.) Tightening 1997 Stratus/Cirrus/Breeze ........................................................................................................... 203 Nm (150 ft. lbs.) to 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 6003 Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque .................................................................................................................................... ................................ 109 - 150 Nm (80 - 110 ft. lbs.) Lug Nut Hex Size .............................................. .......................................................................................................................................................... 19 mm Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 6004 Wheel Fastener: Specifications Wheel Stud Size Stud Size ............................................................................................................................................. ............................................................ M12 x 1.5 mm Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6005 Wheel Fastener: Service Precautions CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6006 Wheel Fastener: Description and Operation If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. Use the procedure and special tools shown in the service procedures section for the wheel mounting studs when replacing the wheel attaching studs. The hub and bearing assembly does not require removal from the steering knuckle or the rear knuckle to replace the wheel attaching studs in the hub and bearing assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6007 Wheel Fastener: Service and Repair CAUTION: If a wheel mounting stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. NOTES: - The following procedure and special tools shown MUST be used-when replacing wheel attaching studs. - The hub and bearing assembly does not require removal from the steering knuckle to replace wheel attaching studs in the hub and bearing assembly. REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. 3. Remove front disc brake caliper to steering knuckle attaching bolts. 4. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6008 5. Support brake caliper/adapter assembly using a wire hook and not by hydraulic hose. Fig. 60 6. Remove braking disc from front hub. 7. Install a lug nut on wheel stud to be removed from hub and bearing assembly, so threads on stud are even with end of lug nut. Rotate hub so stud requiring removal is aligned with notch cast into front of steering knuckle. Install Remover, Special Tool C-4150 on hub and bearing assembly flange and wheel stud. 8. Tighten down on special tool, this will push the wheel stud out of the hub and bearing flange. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6009 Fig. 62 INSTALL 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install braking disk back on front hub. 4. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 5. Install disc brake caliper assembly to steering knuckle attaching bolts and torque to 31 Nm (23 ft. lbs.). 6. Install front wheel and tire assembly. Install front wheel lug nuts and torque to 129 Nm (95 ft. lbs.). 7. Lower vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams Air Door Actuator / Motor: Diagrams BLEND DOOR ACTUATOR Mode Door Actuator Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 6015 Air Door Actuator / Motor: Description and Operation CIRCUIT OPERATION Mode Door Actuator (Manual A/C) The mode door actuator is located on the lower left side of the A/C-Heater housing. This actuator controls the position of the panel/bi-level door and the floor/defrost door. Power for the mode door actuator is provided by the Body Control Module (BCM) on the C26 circuit. This is a 5 volt feed. Circuit C35 is the mode drive circuit from the BCM to the actuator. The C37 circuit is the feedback from the actuator to the BCM. The BCM uses this information to adjust the door to the proper position. Circuit C57 is the sensor return to the BCM. This circuit is spliced with the blend air door actuator. Circuit C34 is the common line that is spliced, and connects, to the blend air door actuator and the recirculation door actuator. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 6016 Air Door Actuator / Motor: Testing and Inspection Fig 9 Mode Door Motor Location NOTE: If battery voltage is low or not sensed at the actuator/motor for less than a (60) second interval, the actuator/motor will be out of calibration. Remove the M1 (I.O.D.) fuse for a minimum of (60) seconds. The actuator/motor will then self calibrate itself upon reinstallation of fuse. The mode door actuator is an electric motor. It mechanically positions the A/C unit panel/bi-level door and the floor/defrost door. Prior to part replacement, re-calibration of the HVAC actuator is recommended. Calibration is performed by disconnecting the battery negative cable or the removal of the instrument panel M-1 fuse. Electrical power should be re-established after (60) seconds which will automatically initiate the software calibration procedure. If this procedure fails, it will be necessary to replace the mode door actuator/motor. The mode door actuator/motor is not serviceable and must be replaced if found to be defective. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 6017 Air Door Actuator / Motor: Service and Repair Fig 9 Mode Door Motor Location NOTE: If battery voltage is low or not sensed at the actuator/motor for less than a (60) second interval, the actuator/motor will be out of calibration. Remove the M1 (I.O.D.) fuse for a minimum of (60) seconds. The actuator/motor will then self calibrate itself upon reinstallation of fuse. The mode door actuator is an electric motor. It mechanically positions the A/C unit panel/bi-level door and the floor/defrost door. Prior to part replacement, re-calibration of the HVAC actuator is recommended. Calibration is performed by disconnecting the battery negative cable or the removal of the instrument panel M-1 fuse. Electrical power should be re-established after (60) seconds which will automatically initiate the software calibration procedure. If this procedure fails, it will be necessary to replace the mode door actuator/motor. The mode door actuator/motor is not serviceable and must be replaced if found to be defective. The mode door actuator is located on the upper left side of the A/C-Heater housing. Fig 10 Mode Motor Connector REMOVAL 1. Disconnect battery negative cable. 2. Remove left underpanel silencer/duct. 3. Remove electrical connection on actuator. 4. Remove actuator retaining screws. Then pull actuator straight down. Upon removal, note the shaft position of the actuator, because the shaft on this motor is keyed. When installing new actuator, its shaft must be positioned in the same location. INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Recirculation Door Cable Adjustment Air Door Cable: Adjustments Recirculation Door Cable Adjustment The cables must be adjusted for proper function of the control module. To adjust the cable: - Attach the cable to the lever arm of the control module. - Turn the knob fully counterclockwise. - Pull the cable jacket away from the cable end until taut. - Clip the cable jacket to the control module. The knob should travel a full 180° if the cable is properly adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Recirculation Door Cable Adjustment > Page 6022 Air Door Cable: Adjustments Temperature Control Cable Adjustment The cables must be adjusted for proper function of the control module. To adjust the cable: - Attach the cable to the lever arm of the control module. - Turn the knob fully counterclockwise. - Pull the cable jacket away from the cable end until taut. - Clip the cable jacket to the control module. The knob should travel a full 180° if the cable is properly adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Recirculation Door Cable Replacement Air Door Cable: Service and Repair Recirculation Door Cable Replacement Fig 65 Recirculation Cable Location NOTE: The RECIRC door is actuated by a cable which mechanically positions the door. The RECIRC door actuator is located at the far right of the A/C Heater housing near the right A-pillar. Fig 66 Trim Bezel REMOVAL 1. Place the ignition key in the OFF position before removing control module. 2. Remove trim bezel. Fig 67 Control Module Screws 3. Remove cluster hood bezel retaining screws in the trim bezel opening. 4. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Recirculation Door Cable Replacement > Page 6025 5. Remove the cubby bin/cigar lighter bezel and wiring. 6. Remove the control module retaining screws. Fig 68 Control Module At Bezel Opening 7. Drop the A/C control module into the cigar lighter/cubby bin bezel opening. Then disconnect the wiring on the rear of the control module. 8. Release the recirculation cable retaining clip from the top of the control module. Retain the clip for future use. Then disconnect the recirculation control cable. 9. Remove right under panel silencer/duct. Fig 69 Disconnect Recirculation Cable 10. Disconnect cable flag at right of recirculation housing. 11. Remove cable core end from recirculation actuator lever. INSTALLATION For installation, reverse the above procedures. Verify that the cables are property adjusted, free of interference, and the module is seated properly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Recirculation Door Cable Replacement > Page 6026 Air Door Cable: Service and Repair Temperature Control Cable Replacement Fig 66 Trim Bezel NOTES: - The blend-air (temperature) door is actuated by a cable which mechanically positions the temperature door. - The temperature door actuator is located at the center of the A/C Heater housing at the center tunnel. REMOVAL 1. Place the ignition key in the OFF position before removing control module. 2. Remove trim bezel. Fig 67 Control Module Screws 3. Remove cluster hood bezel retaining screws in the trim bezel opening. 4. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws. 5. Remove the cubby bin/cigar lighter bezel and wiring. 6. Remove the control module retaining screws. 7. Remove control module and disconnect the wire connectors. 8. Release the temperature control cable retaining clip from the top of the control module. Retain the clip for future use. Then disconnect the temperature control cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Recirculation Door Cable Replacement > Page 6027 Fig 73 Temperature Cable At A/C Housing 9. Disconnect cable at A/C housing. 10. Remove cable core end from temperature actuator lever. INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation Blower Motor: Description and Operation CIRCUIT OPERATION With the ignition switch is in the RUN position, power flows from the 30 amp fuse located in the junction block, cavity 1, to the blower motor. Blower motor speed is controlled by the fan control switch located in the A/C-Heater control head, and by the resistor block. Blower motor LOW speed operation is accomplished on the C4 circuit. When the control switch is moved to the LOW speed position, current flows from the C1 circuit to the blower motor resistor. Internal to the resistor circuit C1 changes to C73. Power flows from the resistor, on circuit C73, through the blower motor back to the resistor. Voltage is passed through the resistor to circuit C4. Circuit C4 connects from the resistor block to the fan control switch. Ground flows through the switch to the Z1 circuit. The Z1 circuit terminates at a grounding point located at the instrument panel left side cowl. The operation of blower motor M1 and M2 speed operations is the same as the LOW speed except that circuit C5 is used for the M1 speed, and circuit C6 is used for the M2 speed operation. Blower motor HIGH speed operation is accomplished on the C7 circuit. There are no resistors used in the HIGH speed mode. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 6031 Blower Motor: Testing and Inspection - Check the 10 amp fuse located in cavity 9 of the junction block. - Check the 40 amp fuse located in cavity 19 of the PDC. - Check the 30 amp fuse located in cavity 1 of the junction block. - Check for a good ground at the instrument panel left side cowl. - Check for a good ground at the left strut tower. - Check the A/C refrigerant level. The system will not operate with a low level of refrigerant. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 6032 Blower Motor: Service and Repair Fig 13 Blower Motor Wiring NOTE: The blower motor is located on the right side of the heater housing. REMOVAL 1. Disconnect battery. 2. Remove lower right under panel silencer duct. 3. Remove blower motor connector from resistor block. 4. Remove blower motor case retaining screws. Fig 14 Blower Motor 5. Lower blower motor case from housing. 6. Remove fan scroll from motor shaft. 7. Remove motor from motor case. INSTALLATION For installation, reverse the above procedures. NOTE: The blower motor wheel is only serviced with the blower motor The wheel and the motor are balanced as an assembly. If the blower motor wheel requires replacement, the blower motor must also be replaced. Refer to blower motor for replacement procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation Blower Motor Relay: Description and Operation This system uses no blower motor relay. Motor is controlled by the fan control switch in the heater control head and by the blower motor resistor block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Fig 15 Blower Motor Resistor NOTE: The blower motor resistor is located on the lower right side of the heater housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6039 Blower Motor Resistor: Service and Repair Fig 15 Blower Motor Resistor NOTE: The blower motor resistor is located on the lower right side of the heater housing. REMOVAL 1. Remove lower right underpanel silencer/duct. 2. Disconnect wiring connectors on blower motor resistor. 3. Remove blower motor resistor retaining screws. 4. Pull blower motor resistor out of heater housing. INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications Compressor Clutch: Electrical Specifications Rated Voltage ...................................................................................................................................... ..................................................................... 12 VDC Minimum Breakaway Torque ................................................................................................................................ 31.4 Nm (23 ft lb, 3.2 Kgf.m) at 12VDC Minimum Engagement Voltage ............................................................................................................................................ 7.5 AT AIR GAP 0.5 mm REF Power Consumption ....................................................................................... .......................................................................................... 50 WATTS MAX. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications > Page 6045 Compressor Clutch: Mechanical Specifications Clutch Air Gap ..................................................................................................................................... ...................................................... (0.013 - 0.025 in.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6046 Compressor Clutch: Description and Operation CLUTCH, PULLEY AND COIL They are mounted on the compressor providing a way to drive the compressor. The compressor clutch and coil are the only serviced parts on the compressor. When the compressor is not in operation, the pulley free wheels on the clutch hub bearing. When the coil is energized the clutch plate is magnetically engaged with the pulley and turns the compressor shaft. The clutch assembly consists of a stationary electromagnetic coil, hub bearing pulley assembly, and clutch plate. The electromagnetic coil and pulley are retained on the compressor with snap rings. The clutch plate is mounted on the compressor shaft and secured with a nut. When the compressor is not operating, the pulley free wheels on the hub bearing which is part of the pulley When the coil is energized the plate is magnetically engaged with the pulley and turns the compressor shaft. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In Compressor Clutch: Service and Repair Clutch Break-In After installing a new field coil-core, check for correct voltage/amperage. Cycle the A/C clutch approximately 20 times (5 seconds on and 5 seconds off). For this procedure run engine at 1,500 to 2,000 rpm and set the system to MAX A/C mode. This burnishing procedure will seat the opposing friction surfaces and provide a higher clutch torque capability. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In > Page 6049 Compressor Clutch: Service and Repair Compressor Clutch / Coil Assembly Replacement Fig 21 Compressor Shaft Nut Removal/Installation REMOVAL 1. Remove the compressor from the mount. 2. Install two (6 mm) bolts into the threaded holes in the armature plate. Hold bolts with two wrenches to prevent shaft from turning. Remove compressor shaft nut. Fig 22 Clutch Plate/Pulley/Field Coil 3. Lightly tap clutch plate with a plastic hammer and remove plate and shim(s)). CAUTION: Do not use screwdrivers between the armature plate assembly and rotor-pulley to remove the armature plate. This may damage the armature plate assembly. 4. Remove pulley retaining snap ring with snap ring pliers. Remove pulley assembly from compressor. Use a plastic hammer, if necessary. 5. Loosen the lead wire retaining clamps and remove lead wire from the compressor front end cover. Disconnect the lead wire from the thermal limiter switch. 6. Remove snap ring which secures field coil-core assembly to the front cover. Note the alignment of field coil-core assembly when removing. WARNING: Take care that the snap ring does not fly out from the groove. INSPECTION Examine frictional faces of the rotor-pulley and armature plate for wear. The pulley and 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 excess oil. If excess oil is present, the shaft seal is leaking and the compressor must be replaced. Check pulley hub bearing for roughness or excessive grease leakage. Check for bearing grease contamination on armature plate faces. CAUTION: The pulley and clutch 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 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In > Page 6050 1. Position the back of the field coil on the compressor front cover. Be sure the locating nipple on the back of the coil lines up with the locating indentation on the front cover. This ensures correct position of the coil and lead wire. 2. Fasten lead wire to the compressor front cover with the retaining clip. Connect the lead wire to the thermal limiter switch. 3. Install field coil retaining snap ring (bevel side outward) with snap ring pliers. Insure snap ring is properly seated into groove. CAUTION: If snap rings on field coil or pulley assembly are not fully seated, they will vibrate out. A clutch failure and possible severe damage to the compressor could result. 4. Position pulley assembly onto compressor. CAUTION: Do not mar the pulley frictional surface. 5. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Insure snap ring is properly seated into groove. 6. Place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the compressor shaft. Fig 23 Aligning Clutch Plate Splines 7. Install clutch plate on compressor shaft. Note the machined mating splines. Fig 24 Measuring Air Gap 8. With the front clutch plate assembly tight against the shims, measure the air gap between clutch plate and pulley face with feeler gauges. The air gap should be between 0.35 and 0.65 mm (0.013 and 0.025 inch). If proper air gap is not obtained, add or subtract shims until desired air gap is obtained. 9. Install compressor shaft nut. Tighten nut to 17.6 Nm (13 ft lb) torque. 10. Shims may compress after tightening shaft bolt. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. 11. Install the compressor onto the mount. CLUTCH BREAK-IN After installing a new field coil-core, check for correct voltage/amperage. Cycle the A/C clutch approximately 20 times (5 seconds on and 5 seconds off). For this procedure run engine at 1,500 to 2,000 rpm and set the system to MAX A/C mode. This procedure will seat the opposing friction surfaces and provide a higher clutch torque capability. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection 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 2 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 4.15 amperes at 11.5 to 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. 6. If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 5 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center Relay is in the Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Description and Operation Compressor Fitting HVAC: Description and Operation The refrigerant system service ports are used to charge,recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port fitting sizes are used on the R-134a system, to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment. The high pressure service port is located on the compressor manifold or plumbing, near the front of the engine compartment. The low pressure service port is located on the suction line, near the front of the engine compartment. After servicing the refrigerant system, always reinstall the service port caps. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 24-04-98 > Apr > 98 > A/C System - Performance Complaints Technical Service Bulletin # 24-04-98 Date: 980417 A/C System - Performance Complaints NO: 24-04-98 GROUP: Air Conditioning DATE: Apr. 17, 1998 SUBJECT: A/C System Performance MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible SYMPTOM/CONDITION: A/C performance complaints and/or A/C compressor failure (seized) in high ambient temperatures (90°+ F). This condition is aggravated by start and stop city driving and/or extended periods of idling with the A/C running. DIAGNOSIS: If the vehicle is operated in high ambient temperatures or A/C compressor has failed (seized) or system passes the Performance Test Procedure as described on page 24-5 of the 1998 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-8121) perform the Repair Procedure. PARTS REQUIRED: 1 05011395AA Kit, A/C Condenser Contains: A/C Condenser Foam Seals, Radiator to Condenser Label, Refrigerant Charge Level 1 04796282AB Kit, Retaining Strap Transmission Cooler 5 06502625 Retainer, Fascia AR(1) 04886129AA SP-15 PAG Oil AR(1) 04883308 Air Seal, Radiator Right Side AR(1) 04883308 Air Seal, Radiator Left Side POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-45-05-93 Condenser Replace 1995-97 (JA) 1.4 Hrs. 1996-97 (JX) 1.4 Hrs. 1998 (JA,JX) 0.9 Hrs. 24-45-05-62 Optional Equipment- 1995-98 (JA) 0.2 Hrs. Transmission Oil 1996-98 (JX) 0.2 Hrs. Cooler Equipped 24-01-02-01 System Test, 1998 (JA,JX) 0.6 Hrs. Recovery, & Recharge-A/C FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a revised A/C condenser and radiator air seals as necessary. 1. Release hood latch and open hood. 2. Remove refrigerant from the A/C system using a refrigerant recovery machine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 24-04-98 > Apr > 98 > A/C System - Performance Complaints > Page 6068 3. Remove push-in fasteners holding top of fascia and/or grille assembly to radiator closure panel cross member. 4. Remove push-in screw and retainers holding the fascia to bottom of lower cross member and bottom of splash shields. 5. Using a trim stick, pry wheelhouse edges from behind the fascia forward of front wheels. 6. Remove screws holding fascia to bottom of fenders rearward of the parking lamps. 7. Slide the fascia forward to disengage hooks holding the fascia to bottom of fenders. 8. Separate the fascia from the vehicle. 9. Disengage fog lamp wire connectors from the back of fog lamps, if equipped. 10. Remove power steering cooler attaching screw, ambient temperature sensor attaching screw, if equipped, and pencil braces. Remove bumper reinforcement beam (face bar). 11. Remove the upper radiator cross member and set on top of the engine. It is not necessary to remove hood release cable from cross member. 12. Remove condenser refrigerant lines. Use Miller Special Tool kit # 7193 for quick disconnect couplers. 13. Remove (4) A/C condenser to radiator attaching screws. 14. Remove A/C condenser tube attaching the bracket on right side edge of the radiator. 15. On vehicles equipped with a transmission fluid auxiliary cooler, cut the retaining straps and move cooler out of the way. Save the spacers. On 2.5L engine equipped vehicles the longer cooler line must be removed from the cooler. 16. Remove the condenser from the vehicle. 17. If the vehicle is not equipped with side air shields, slide air seals p/n's 04883308/9, between radiator and condenser, position over condenser mounting brackets (Figure 1). 18. Install foam seals on the radiator side of the new condenser. Position seals along sides and across top of the condenser. 19. Position the new condenser in the vehicle. 20. Install right side condenser tube support bracket, start the screw, do not tighten. 21. Install transmission fluid auxiliary cooler to the condenser with new retaining strap kit, p/n 04796282AB. NOTE: DO NOT ADD MORE THAN ONE (1) OZ. OF REFRIGERANT OIL. EXCESSIVE OIL WILL DEGRADE COOLING PERFORMANCE. 22. Install and tighten (4) A/C condenser to radiator attaching screws. 23. Tighten the A/C condenser tube attaching bracket on right side of the radiator. 24. Add one (1) oz. of refrigerant oil, SP-15 PAG, Mopar p/n 04886129AA, for condenser replacement. Additional oil will be required if additional Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 24-04-98 > Apr > 98 > A/C System - Performance Complaints > Page 6069 components are replaced. Refer to the oil capacity chart on page 24-7 of the 1998 Breeze/Cirrus/Stratus (Publication No. 81-270-8121). 25. Connect NO condenser refrigerant lines. 26. Install bumper reinforcement beam, fascia, headlamps, and upper radiator cross member. Use new fascia to lower cross member attaching screws/retainer, p/n 06502625. 27. Charge A/C system using a refrigerant recovery machine. JA/JX charge with 20 oz. (1.250 lbs.) of R-134A refrigerant. 28. Install refrigerant charge level label in visible area on upper radiator cross member. 29. On 2.5L engine equipped vehicles, some transmission fluid may be lost when the auxiliary cooler line is removed. Check transmission fluid level and top off with Mopar Automatic Transmission Fluid ATF+2 Type 7176, p/n 04762644. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 24-04-98 > Apr > 98 > A/C System Performance Complaints Technical Service Bulletin # 24-04-98 Date: 980417 A/C System - Performance Complaints NO: 24-04-98 GROUP: Air Conditioning DATE: Apr. 17, 1998 SUBJECT: A/C System Performance MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible SYMPTOM/CONDITION: A/C performance complaints and/or A/C compressor failure (seized) in high ambient temperatures (90°+ F). This condition is aggravated by start and stop city driving and/or extended periods of idling with the A/C running. DIAGNOSIS: If the vehicle is operated in high ambient temperatures or A/C compressor has failed (seized) or system passes the Performance Test Procedure as described on page 24-5 of the 1998 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-8121) perform the Repair Procedure. PARTS REQUIRED: 1 05011395AA Kit, A/C Condenser Contains: A/C Condenser Foam Seals, Radiator to Condenser Label, Refrigerant Charge Level 1 04796282AB Kit, Retaining Strap Transmission Cooler 5 06502625 Retainer, Fascia AR(1) 04886129AA SP-15 PAG Oil AR(1) 04883308 Air Seal, Radiator Right Side AR(1) 04883308 Air Seal, Radiator Left Side POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-45-05-93 Condenser Replace 1995-97 (JA) 1.4 Hrs. 1996-97 (JX) 1.4 Hrs. 1998 (JA,JX) 0.9 Hrs. 24-45-05-62 Optional Equipment- 1995-98 (JA) 0.2 Hrs. Transmission Oil 1996-98 (JX) 0.2 Hrs. Cooler Equipped 24-01-02-01 System Test, 1998 (JA,JX) 0.6 Hrs. Recovery, & Recharge-A/C FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing a revised A/C condenser and radiator air seals as necessary. 1. Release hood latch and open hood. 2. Remove refrigerant from the A/C system using a refrigerant recovery machine. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 24-04-98 > Apr > 98 > A/C System Performance Complaints > Page 6075 3. Remove push-in fasteners holding top of fascia and/or grille assembly to radiator closure panel cross member. 4. Remove push-in screw and retainers holding the fascia to bottom of lower cross member and bottom of splash shields. 5. Using a trim stick, pry wheelhouse edges from behind the fascia forward of front wheels. 6. Remove screws holding fascia to bottom of fenders rearward of the parking lamps. 7. Slide the fascia forward to disengage hooks holding the fascia to bottom of fenders. 8. Separate the fascia from the vehicle. 9. Disengage fog lamp wire connectors from the back of fog lamps, if equipped. 10. Remove power steering cooler attaching screw, ambient temperature sensor attaching screw, if equipped, and pencil braces. Remove bumper reinforcement beam (face bar). 11. Remove the upper radiator cross member and set on top of the engine. It is not necessary to remove hood release cable from cross member. 12. Remove condenser refrigerant lines. Use Miller Special Tool kit # 7193 for quick disconnect couplers. 13. Remove (4) A/C condenser to radiator attaching screws. 14. Remove A/C condenser tube attaching the bracket on right side edge of the radiator. 15. On vehicles equipped with a transmission fluid auxiliary cooler, cut the retaining straps and move cooler out of the way. Save the spacers. On 2.5L engine equipped vehicles the longer cooler line must be removed from the cooler. 16. Remove the condenser from the vehicle. 17. If the vehicle is not equipped with side air shields, slide air seals p/n's 04883308/9, between radiator and condenser, position over condenser mounting brackets (Figure 1). 18. Install foam seals on the radiator side of the new condenser. Position seals along sides and across top of the condenser. 19. Position the new condenser in the vehicle. 20. Install right side condenser tube support bracket, start the screw, do not tighten. 21. Install transmission fluid auxiliary cooler to the condenser with new retaining strap kit, p/n 04796282AB. NOTE: DO NOT ADD MORE THAN ONE (1) OZ. OF REFRIGERANT OIL. EXCESSIVE OIL WILL DEGRADE COOLING PERFORMANCE. 22. Install and tighten (4) A/C condenser to radiator attaching screws. 23. Tighten the A/C condenser tube attaching bracket on right side of the radiator. 24. Add one (1) oz. of refrigerant oil, SP-15 PAG, Mopar p/n 04886129AA, for condenser replacement. Additional oil will be required if additional Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 24-04-98 > Apr > 98 > A/C System Performance Complaints > Page 6076 components are replaced. Refer to the oil capacity chart on page 24-7 of the 1998 Breeze/Cirrus/Stratus (Publication No. 81-270-8121). 25. Connect NO condenser refrigerant lines. 26. Install bumper reinforcement beam, fascia, headlamps, and upper radiator cross member. Use new fascia to lower cross member attaching screws/retainer, p/n 06502625. 27. Charge A/C system using a refrigerant recovery machine. JA/JX charge with 20 oz. (1.250 lbs.) of R-134A refrigerant. 28. Install refrigerant charge level label in visible area on upper radiator cross member. 29. On 2.5L engine equipped vehicles, some transmission fluid may be lost when the auxiliary cooler line is removed. Check transmission fluid level and top off with Mopar Automatic Transmission Fluid ATF+2 Type 7176, p/n 04762644. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 6077 Condenser HVAC: Specifications Refrigerant Oil Capacity 30 ml (1 oz) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 6078 Condenser HVAC: Description and Operation It is located in front of the engine cooling radiator. Its function is to cool the hot high pressure refrigerant gas. This causes it to condense into a high pressure liquid refrigerant. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 6079 Condenser HVAC: Service and Repair Fig 25 Grille Retainers NOTE: The condenser is located between the radiator and the front bumper. The condenser can be serviced without having to drain the cooling system or remove the radiator. WARNINGS: - Avoid breathing a/c refrigerant and lubricant vapor or mist exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to reclaim R-134a systems. If accidental system discharge occurs, ventilate work area before resuming service. - R-134a service equipment or vehicle a/c system should not be pressure tested or leak tested with compressed air. Some mixtures of air and R-l34a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Disconnect and cap A/C lines at the condenser. 3. Remove grille retainers. Fig 26 Radiator Support Crossmember 4. Remove upper radiator support crossmember. 5. Remove condenser lines. Use Special Tool kit 7193 for quick disconnect couplers. 6. Remove radiator fan module mounts. 7. Remove condenser line support bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 6080 Fig 27 Condenser Mounting 8. Remove condenser mounting bolts. CAUTION: Avoid bending or breaking condenser inlet tube when lifting condenser from the vehicle. Fig 28 Condenser Removal 9. Lift condenser from vehicle. INSTALLATION For installation, reverse above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Assembly: > 08-06-98 > Feb > 98 > A/C - EBL Indicator Bulb Does Not Light Control Assembly: Customer Interest A/C - EBL Indicator Bulb Does Not Light NO: 08-06-98 GROUP: Electrical DATE: Feb. 27, 1998 SUBJECT: "EBL" indicator Bulb Does Not Light THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-38-96 DATED NOVEMBER 8, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THE 1998 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH **ASTERISKS". MODELS: 1995 - **1998** (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Electric Back Light (EBL) indicator bulb in the HVAC control module does not light, but defogger grid functions normally. DIAGNOSIS: Use the following steps to diagnose this condition: 1. Verify the indicator bulb does not light and the defogger grid functions normally. 2. Check fuse # 6 in the junction block (fuse # 6 powers the indicator light and the heated rear view mirrors). If fuse # 6 is improperly installed, missing or blown, repair or replace as necessary. 3. If fuse # 6 is OK (heated rear view mirrors function) check that the 8-way connector is properly installed In the back of the HVAC control module. 4. If the 8-way connector is installed properly perform the diagnosis on page 8N-1 of the 1997 Breeze/Cirrus/Stratus service manual (Publication No. 81-270-7121). POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 08-06-98 > Feb > 98 > A/C - EBL Indicator Bulb Does Not Light Control Assembly: All Technical Service Bulletins A/C - EBL Indicator Bulb Does Not Light NO: 08-06-98 GROUP: Electrical DATE: Feb. 27, 1998 SUBJECT: "EBL" indicator Bulb Does Not Light THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-38-96 DATED NOVEMBER 8, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THE 1998 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH **ASTERISKS". MODELS: 1995 - **1998** (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Electric Back Light (EBL) indicator bulb in the HVAC control module does not light, but defogger grid functions normally. DIAGNOSIS: Use the following steps to diagnose this condition: 1. Verify the indicator bulb does not light and the defogger grid functions normally. 2. Check fuse # 6 in the junction block (fuse # 6 powers the indicator light and the heated rear view mirrors). If fuse # 6 is improperly installed, missing or blown, repair or replace as necessary. 3. If fuse # 6 is OK (heated rear view mirrors function) check that the 8-way connector is properly installed In the back of the HVAC control module. 4. If the 8-way connector is installed properly perform the diagnosis on page 8N-1 of the 1997 Breeze/Cirrus/Stratus service manual (Publication No. 81-270-7121). POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 6094 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 6095 Control Assembly: Description and Operation A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 6096 Control Assembly: Testing and Inspection Temperature Reference Chart NOTE: The control switch and timer circuit may be tested in the vehicle with or without scan tool (DRB). TESTING WITH SCAN TOOL If using the scan tool, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection/Procedures/Diagnostic Charts. TESTING WITHOUT SCAN TOOL 1. Remove the control switch from console and disconnect control switch. 2. Using a ohmmeter, check leads between Pins 5 and 8 of the 8-Way connector. Turn the control module to each position shown on chart below. The resistance reading should be within the specifications shown. Switch Position Ohm Range Panel 828 to 856 ohms Bi-Level 1.279k to 1.315k ohms Floor 2.302k to 2.358k ohms Mix 5.202k to 5.318k ohms Defrost 99.5k to 101.5k ohms If not OK, replace the control module. If OK, check: Blown fuse - Cut wire - Poor ground - Poor connection - Defective BCM - Bulkhead connector inoperative Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 6097 Control Assembly: Service and Repair CIRCUIT OPERATION A/C - Heater Control The air conditioning-heater system is controlled by the Body Control Module (BCM). The BCM sends out voltage to the A/C-Heater control on circuit C58. The control uses resistors to internal to the control. These resistors are connected to the Z2 ground circuit. When the operator requests a function in the system the BCM measures the voltage drop, on circuit C58, and activates the mode actuator door to the proper position. A separate A/C switch is used in the system. This switch works the same as the mode actuator switches. When the operator presses the switch the BCM measures the voltage drop in the C21 circuit and activates the proper functions. Internal to the A/C-Heater control the A/C switch is connected to the blower motor switch. This allows the A/C system to only operate when the blower switch in an ON position. Ground for the A/C switch is provided through the blower motor switch to the Z1 circuit. This circuit terminates at the instrument panel left side cowl. A Light Emitting Diode (LED) is connected in the C21 circuit and illuminates when the A/C system is operating. Illumination lamps and LED's are internal to the control. These are controlled by the BCM. The E2 circuit from the BCM provides the voltage to the control for lamp and LED illumination. Ground for the lamps and LED's is provided on the Z1 circuit which terminates at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation Control Module HVAC: Description and Operation SYSTEM OPERATION HVAC Control Module HVAC Control Module The rear window control switch and circuit are integrated into the HVAC control module. When actuating the switch it sends a ground signal to the Body Control Module (BCM). The BCM actuates the relay allowing current to flow through the grid lines for ten minutes upon initial actuation. Then 5 minutes with each subsequent actuation or until either the switch or ignition is turned off. An indicating lamp illuminates the rear window defogger switch. CIRCUIT OPERATION A/C - Heater Control The air conditioning-heater system is controlled by the Body Control Module (BCM). The BCM sends out voltage to the A/C-Heater control on circuit C58. The control uses resistors to internal to the control. These resistors are connected to the Z2 ground circuit. When the operator requests a function in the system the BCM measures the voltage drop, on circuit C58, and activates the mode actuator door to the proper position. A separate A/C switch is used in the system. This switch works the same as the mode actuator switches. When the operator presses the switch the BCM measures the voltage drop in the C21 circuit and activates the proper functions. Internal to the A/C-Heater control the A/C switch is connected to the blower motor switch. This allows the A/C system to only operate when the blower switch in an ON position. Ground for the A/C switch is provided through the blower motor switch to the Z1 circuit. This circuit terminates at the instrument panel left side cowl. A Light Emitting Diode (LED) is connected in the C21 circuit and illuminates when the A/C system is operating. Illumination lamps and LED's are internal to the control. These are controlled by the BCM. The E2 circuit from the BCM provides the voltage to the control for lamp and LED illumination. Ground for the lamps and LED's is provided on the Z1 circuit which terminates at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Page 6101 Control Module HVAC: Service and Repair Fig 29 Control Module NOTE: The control module is located below the radio. REMOVAL 1. Place the ignition key in the OFF position before removing control module. 2. Remove trim bezel. Fig 30 Control Module Screws 3. Remove cluster hood bezel retaining screws in the trim bezel opening. 4. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws. 5. Remove the cubby bin/cigar lighter bezel and wiring. 6. Remove the control module retaining screws. Fig 31 Control Module At Bezel Opening Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Page 6102 7. Drop the A/C control module into the cigar lighter/cubby bin bezel opening. Then disconnect the wiring on the rear of the control module. 8. Release the cable clips from the top of the control module. Retain the clips for future use. Then disconnect the temperature control and recirculation control cables. 9. Remove the control module. INSTALLATION For installation reverse the above procedures. Verify that the cables are properly adjusted and the module is seated properly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation Coupler HVAC: Description and Operation Fig 12 Spring Lock Coupler Disconnect Spring-locking refrigerant line couplers are used to connect refrigerant lines and other components to the refrigerant system. The coupling is held together by a garter spring inside a circular cage. When the coupling halves are connected, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Secondary clips are installed over the coupling at the factory for added blowoff protection. O-rings are used to seal the coupling. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Page 6106 Coupler HVAC: Service and Repair Fig 12 Spring Lock Coupler Disconnect A/C Line Disconnect Tool 7193 WARNING: Review the Service Precautions before leak testing the system. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary clip from the coupler. Fit the appropriate spring lock refrigerant line coupler tool from the A/C Tool Kit (Special Tool 6125) to the coupler. 3. Close the tool and push it into the open side of the cage to expand the garter spring and release the female fitting. NOTE: The garter spring may not release if the tool is cocked while pushing it into the cage opening. 4. After the garter spring is expanded, pull the fittings apart within the tool. 5. Remove the tool from the disconnected coupler. 6. Separate the two ends of the coupler. INSTALLATION 1. Check to ensure that the garter spring is in the cage of the male coupler fitting. If the garter spring is missing, install a new spring by pushing it into the cage opening. If the garter spring is damaged, remove it from the cage with a small wire hook (DO NOT use a screwdriver) and install a new garter spring. 2. Clean any dirt or foreign material from both halves of the coupling. 3. Install new O-rings on the male fitting. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-ring may allow the connection to leak intermittently during vehicle operation. 4. Lubricate the male fitting and O-ring, and the inside of the female fitting with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 5. Fit the female fitting to the male fitting and push together until the garter spring snaps over the flared end of the female fitting. 6. Ensure the coupler is fully engaged by pulling back on the lines on either side of the coupler. 7. Install the secondary clip on the coupler. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International 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 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 6115 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 6116 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International 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 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 6122 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 6123 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > A/C , Heater - Odors/Defroster Will Not Clear Glass Evaporator Core: Technical Service Bulletins A/C , Heater - Odors/Defroster Will Not Clear Glass NO: 24-14-96 GROUP: Heater & A/C DATE: Sep. 27, 1996 SUBJECT: A/C Evaporator Odor And/Or Incomplete Defrost In "Recirc" Mode MODELS: 1995 - 1997 (PL) Neon 1995 - 1997 (JA) Stratus/Cirrus/Breeze 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: A temporary musty odor may be emitted from the A/C ducts and/or the defroster may not be able to completely clear all the glass, when the recirculation mode (Recirc) is used for extended periods of time. DISCUSSION: The vehicles listed above offer a separate rotary knob for independent control of the Fresh (outside air) / "Recirc" (inside air) function. The intent of the independent control of Recirc is: ^ To temporarily allow customers to eliminate dust or outside odors. ^ To get maximum cooldown performance by going into "Recirc" without having to change modes or temperature settings. Prior to January 1995, the A/C evaporator had a chromate coating for long term corrosion protection and a silicate coating to insure that condensate would run off the fins instead of getting in the airstream and coming out the panel outlets. Due to new regulations, a new non-chromate coating process was implemented in January 1995. Under some ambient conditions the new coating may cause the air passing over the evaporator to develop a temporary musty odor. When operated in the "Recirc mode the odor is more noticeable. Also, operating for extended periods in "Recirc" with the A/C off may create and intensify the musty odor. Running in "Recirc" for long periods of time in very cold weather may cause moisture from snow tracked into the car and moisture from the occupants breath to condense on the cold glass and in some cases the defroster may not clear all the glass. Even with the A/C running on mild wet days and running in "Recirc" some fog may remain on areas of the glass. NOTE: CHANGES IN THE 1997 NEON WILL NOT ALLOW THE FRESH/RECIRC DOOR TO STAY IN RECIRC WHEN THE DEFROST MODE IS SELECTED. It is important that the instructions given in the owners manual that recommend that the "Recirc" mode be used for no more than 30 minutes at a time be followed. Encourage customers to operate in Fresh as the normal condition and go to Recirc only for the temporary conditions given above. POLICY: Information only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6128 Evaporator Core: Specifications Refrigerant Oil Capacity 59 ml (2 oz) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6129 Evaporator Core: Description and Operation The coil removes heat and dehumidifies the air before it enters the vehicle. The coil is located in the A/C housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6130 Evaporator Core: Service and Repair Fig 35 A/C Housing NOTE: The Heater A/C housing must be removed from the vehicle when replacing the evaporator. REMOVAL 1. Disconnect battery negative remote cable. CAUTION: The refrigerant must be removed from the system before removing Heater-A/C housing. Use a refrigerant recovery machine. 2. Remove A/C housing from vehicle. 3. Remove recirculation door inlet cover. 4. Remove evaporator temperature probe. Fig 36 Housing Clips 5. Remove clips retaining evaporator housing to heater/distribution housing. Fig 37 Separate Housings Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6131 Fig 38 Housings 6. Separate evaporator housing from heater/distribution housing. 7. Remove seal around evaporator tube inlet. Fig 39 Evaporator Housing Upper Cover 8. Remove evaporator housing upper cover. Fig 40 Remove Evaporator From Housing 9. Lift evaporator out of lower housing. 10. Remove styrofoam seal around evaporator. 11. Transfer evaporator sensor. Place the evaporator sensor in the same location as on the previous evaporator. INSTALLATION To install, reverse removal procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Circuit Information Evaporator Probe: Description and Operation Circuit Information CIRCUIT OPERATION A/C Evaporator Temperature Sensor The A/C evaporator temperature sensor, located in the A/C-Heater housing, provides the Body Control Module (BCM) with the evaporator temperature to prevent the evaporator from freezing. Power for the sensor is provided from the BCM to the sensor on circuit C12. The ground for the sensor is on circuit C57 to the BCM. Information on evaporator temperature is sent to the Powertrain Control Module (PCM) across the CCD Bus. The PCM uses this information to control operation of the A/C compressor clutch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Circuit Information > Page 6137 Evaporator Probe: Description and Operation Evaporator Temperature Sensor EVAPORATOR PROBE The evaporator temperature probe prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow It does this by cycling the compressor clutch on and off. The switch is attached to the evaporator coil with the sensing probe inserted into the coil fins. The evaporator probe is a temperature sensing element located at the coldest point on the face of the evaporator. Output from the probe is sampled by the Body Control Module (BCM). It is used to switch the A/C compressor clutch OFF before evaporator freeze up occurs. The clutch is switched OFF when the probe temperature reaches O.94°C. (33.7°F.). It is allowed to switch ON when the probe temperature reaches 2.05°C. (35.7°F). The evaporator probe is located on the lower right side of the evaporator housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Page 6138 Evaporator Probe: Service and Repair Fig 41 Evaporator Probe Wiring REMOVAL 1. Disconnect battery. 2. Remove right under panel silencer/duct. 3. Disconnect wiring connector for evaporator probe. Fig 42 Evaporator Probe 4. Using a flat blade pry tool pull back on the locking tab. Twist the access plate clockwise one quarter turn and remove plate. Fig 43 Remove Probe 5. Pull probe out of evaporator core. This plate must be pushed inside the A/C unit and orientated in such a way that the plate can be removed. INSTALLATION 1. Install new probe into the evaporator. The new probe must not go into the same hole (in the evaporator core) that the old probe was removed. The evaporator is manufactured with three holes for probe insertion. Insert the probe in the uppermost hole. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Page 6139 2. Install evaporator probe access panel. 3. Connect probe wiring harness. 4. Reconnect battery. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation Expansion Valve: Description and Operation The valve is used to meter refrigerant into the evaporator in accordance with cooling requirements. The valve is located in front of the evaporator coil. The expansion valve is located on the engine side of the dash panel, near the right shock tower. The expansion valve can fail in three different positions (open, closed or restricted). In an Open Position: this will result in a noisy compressor or no cooling. The cause can be a broken spring, broken ball or excessive moisture in the A/C system. If the spring or ball are found to be defective, replace the expansion valve. If excessive moisture is found in the A/C system, recycle the refrigerant. In a Closed Position: There will be low suction pressure and no cooling. This may be caused by a failed power dome or excessive moisture in the A/C system. If the power dome on the expansion valve is found to be defective replace the expansion valve. If excessive moisture is found recycle the refrigerant. A Restricted Orifice: There will be low suction pressure and no cooling. This may be caused by debris in the refrigerant system. If debris is believed to be the cause, recycle the refrigerant and replace the expansion valve and receiver/drier. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 6143 Expansion Valve: Service and Repair Fig 44 Liquid Line Clip Fig 45 Suction Line Clip WARNINGS: - Avoid breathing a/c refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. use only approved service equipment meeting SAE requirements to discharge R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. - R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Some mixtures of air/R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Disconnect clips from expansion valve lines. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 6144 Fig 46 Special Tool 7240 For Liquid Line Fig 47 Special Tool 7242 For Suction Line 3. Use special tool kit 7193 to disconnect quick connectors on expansion valve. Fig 48 Lines At Expansion Valve 4. Remove lines at expansion valve. Fig 49 Expansion Valve Bolts 5. Remove two retaining bolts from expansion valve. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 6145 Fig 50 Expansion Valve 6. Remove expansion valve. 7. Remove expansion valve gasket. CAUTION: Always install a new gasket when replacing expansion valve. INSTALLATION For installation, reverse the above procedures. Tighten new expansion valve to 11 Nm (100 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core is located in the heater-A/C housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the amount of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged. it must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 6149 Heater Core: Service and Repair Fig 29 Control Module NOTE: The heater core is serviceable inside the vehicle. However, if the core has leaked a significant amount of coolant, the A/C housing must be removed. The housing should be disassembled and cleaned thoroughly before heater core replacement. If housing removal is necessary, refer to Service and Repair. REMOVAL 1. Disconnect battery negative remote cable. 2. Remove radio/control module bezel. 3. Remove right instrument panel side trim. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 4. Remove two screws at lower right side support beam. 5. Remove bolt for instrument panel support at A-pillar. 6. Remove left instrument panel side trim. 7. Remove upper instrument panel bezel. 8. Remove lower knee bolster. 9. Remove console screws at instrument panel. 10. Remove gearshift knob. 11. Remove shifter bezel. 12. Remove console screws at rear. Remove rear half of console. 13. Remove front console screws. Remove front half of console. 14. Remove right side instrument panel support strut. 15. Drain coolant. Refer to: "Engine, Cooling and Exhaust : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 16. Remove heater hoses at cowl. 17. Remove heater core cover screws and cover. 18. Remove heater core. INSTALLATION 1. Carefully install new heater core into the heater housing. 2. Fasten heater core cover to housing with screws provided. 3. Reinstall all necessary trim. 4. Fill coolant to level. 5. Reconnect battery. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair Fig 57 Heater Hose Connection At Engine NOTE: The heater hoses used are preformed hoses with quick connect fittings at the engine. These hoses are not serviceable and must be replaced using OEM parts. The hoses are attached at the heater core using spring tension clamps. NOTE: Review Safety Precautions and Warnings before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Using thin slide-jaw pliers, pinch quick connect fitting in, of hose to be removed. 3. Remove intake manifold plenum. Fig 56 Heater Hose Connection At Heater Core 4. Using spring tension clamp pliers, remove clamp at heater core end of hose to be removed. 5. Carefully rotate hose back and forth while tugging slightly away from connector nipple. 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 into heater unit. INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation The valve is located at the rear of the compressor. The valve is used to prevent excessive high system pressure. The valve vents the system when a pressure of 3445-4135 kPa (500-600 psi) and above is reached. This prevents damage to the compressor and other system components. The valve closes with a minimum pressure of 2756 kPa (400 psi). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Refrigerant Oil Capacity All Refrigerant Lines ............................................................................................................................ ....................................................... 44 ml (1.5 oz) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 6159 Hose/Line HVAC: Description and Operation A/C REFRIGERANT LINES The lines are used to carry the refrigerant between the various system components. The air conditioning lines used on this vehicle are made from reinforced rubber with a nylon liner on the inner walls. The ends of the A/C lines are made with light weight aluminium fittings or quick connects. The A/C lines use special connectors called quick connects. There are four quick connects in the system. Two are located at the condenser and the other two are located at the expansion valve. Each quick connector has a clip installed on it. CAUTION: Never attempt to remove a clip or disconnect a quick connect without reclaiming all refrigerant from the air conditioning system. The system must be empty. All quick connects use two O-rings to seal the connection. The O-rings are made from a special type of rubber that is not affected by R-134a refrigerant. O-ring replacement is required whenever lines are removed and installed. Use only O-rings specified for this vehicle. Failure to use the correct type of O-ring will cause the connection to leak within a short period of time. When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a Service equipment or vehicle a/c system should not be pressure tested or leak tested with compressed air. Some mixtures of air/R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert into acids within a closed system. CAUTION: The system must be completely empty before opening any filling or connection in the refrigeration system. Open fillings with caution even after the system has been emptied. If any pressure is noticed as a filling is loosened, retighten fitting and evacuate the system again. A good rule for the flexible hose lines is to keep the radius of all bends at least 10 times the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 3 inches (80 mm) from the exhaust manifold. Inspect all flexible hose lines to make sure they are in good condition and properly routed. The use of correct wrenches when making connections is very important. Improper wrenches or improper use of wrenches can damage the fittings. The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. When opening a refrigeration system, have everything you will need to repair the system ready. This will minimize the amount of time the system must be opened. Cap or plug all lines and fittings as soon as they are opened. This will help prevent the entrance of dirt and moisture. All new lines and components should be capped or sealed until they are ready to be used. All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept clean and dry. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings Hose/Line HVAC: Service and Repair Handling Tubing and Fittings HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert to acids within a closed system. CAUTION: The system must be completely empty before opening any fitting or connection on the refrigerant system. Open fittings with caution even after system has been emptied. If pressure is noticed as a fitting is loosened, tighten fitting and evacuate system again. BENDING FLEX HOSE A good rule for the flexable hose lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharper bends will reduce the flow of the refrigerant. The flexible hose lines should be routed at least 3 inches away from exhaust manifolds. Inspect all flexible hose lines to make sure they are in good condition and properly routed. CAUTION: The use of correct wrenches when making connections is very important. Improper wrenches or the improper use of wrenches can damage the fittings. INTERNAL DAMAGE The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture, or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. OPENING SYSTEM When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or Plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. CAUTION: All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept dry. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 6162 Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Fig 32 Quick Connect Clip Fig 33 Special Tool For Line At Condenser REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Disconnect A/C pressure transducer wire harness. 3. Remove quick connect clip and disconnect quick connect at condenser using Special Tool kit 7193. CAUTION: Cap all lines that are not being replaced and cap the expansion valve tubes. Fig 34 Line At Compressor 4. Disconnect line at A/C compressor. Remove discharge line. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 6163 INSTALLATION For installation, reverse the above procedures. Tighten bolts to 22 Nm (200 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 6164 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Fig 58 Liquid Line Clip At Expansion Valve LIQUID LINE TO EXPANSION VALVE Removal 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Remove A/C quick connect clip at expansion valve. Fig 59 Use Special Tool 7240 For Quick Connect 3. Disconnect quick connector on expansion valve. Remove liquid line from expansion valve. Use Special Tool kit 7193 to disconnect quick connector. CAUTION: Cap all lines that are not being replaced and cap the expansion valve tubes. Fig 60 Liquid Line At Receiver/Drier Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 6165 4. Disconnect liquid line from the receiver/drier. 5. Remove the liquid line from the vehicle. Installation For installation, reverse the above procedures. Fig 61 Clip Removal LIQUID LINE TO CONDENSER Removal 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Remove A/C quick connect clip at condenser. Fig 62 Quick Coupler Using Special Tool 7240 Fig 63 Line At Condenser 3. Disconnect quick connector at condenser. Remove liquid line from condenser. Use special tool kit 7193 to disconnect quick connector. Remove line at condenser. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 6166 CAUTION: Cap all lines that are not being replaced and cap the condenser inlet. Fig 64 Liquid Line At Receiver/Drier 4. Disconnect liquid line from the receiver/drier. 5. Remove the liquid line from the vehicle. Installation For installation reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 6167 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Fig 70 Suction Line Routing Clip REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Remove suction line clip at right strut tower. Fig 71 Quick Connect Clip 3. Remove quick connect clip. Disconnect quick connect at expansion valve end using Special Tool Kit 7193. CAUTION: Cap all lines that are not being replaced and cap the expansion valve tubes. Fig 72 Suction Line At Compressor 4. Disconnect line at compressor end. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Handling Tubing and Fittings > Page 6168 5. Remove suction line from vehicle. INSTALLATION For installation, reverse the above procedures. Tighten bolts to 22 Nm (200 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation Housing Assembly HVAC: Service and Repair Heater-A/C Housing Removal and Installation NOTE: The heater core may be removed without removing the unit housing. Refer to: "Heater Core : Service and Repair" See: Heater Core/Service and Repair WARNINGS: - Avoid breathing a/c refrigerant and lubricant vapor or mist exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to reclaim R-134a systems. If accidental system discharge occurs, ventilate work area before resuming service. - R-134a service equipment or vehicle a/c system should not be pressure tested or leak tested with compressed air. Some mixtures of air and R-l34a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. REMOVAL 1. Disconnect battery negative remote cable. This must be done to prevent accidental air bag deployment. 2. Using an A/C recovery unit, remove all R-134a refrigerant from the A/C system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 3. Remove air cleaner hose and air distribution duct from the engine. 4. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair NOTE: The upper intake manifold has to be removed at this time to access the heater hose connections at the bulkhead. 5. Disconnect heater hoses at the dash panel. Plug the heater core inlet and outlet tubes to prevent antifreeze from spilling on the vehicle interior during removal. If an appropriate plug cannot be found pull back carpet and use caution when removing unit. Keep the heater tubes elevated to prevent spillage of coolant. 6. Remove both A/C lines from expansion valve. Use Special Tool Kit 7193 to disconnect quick connectors on A/C lines. After removing lines cap the expansion valve openings and the A/C hose openings. This will prevent any dirt or moisture from entering the refrigerant system during servicing. CAUTION: The lubricant used in this air conditioning system absorbs moisture readily (similar to brake fluid). Do not leave any portion of the system open for extended periods of time. Fig 66 Trim Bezel 7. Remove trim bezel. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6173 Fig 67 Control Module Screws 8. Remove cluster hood bezel retaining screws in the trim bezel opening. 9. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws. 10. Remove the cubby bin/cigar lighter bezel and wiring. 11. Remove the control module retaining screws. Fig 68 Control Module At Bezel Opening 12. Drop the A/C control module into the cigar lighter/cubby bin bezel opening. Then disconnect the wiring on the rear of the control module. 13. Release the cable clips from the top of the control module. Retain the clips for future use. Then disconnect the temperature control and recirculation control cables. 14. Remove the control module. 15. Remove upper instrument panel bezel. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 16. Remove right and left instrument panel end caps. 17. Remove left lower knee bolster. Disconnect mode door motor wiring. 18. Remove right and left interior door post kick panel. 19. Remove front and rear halves of floor console. 20. Remove the radio. 21. Remove right side lower silencer/duct. 22. Remove glove box assembly 23. Remove right side vertical Support strut brace. 24. Remove left side vertical support strut brace. 25. Remove center lower distribution housing. 26. Remove bolts securing Heater-A/C housing to metal I/P frame. 27. Remove upper instrument panel cowl trim cover. 28. Disconnect steering column from instrument panel. Lower steering column. 29. Remove instrument panel bolts at cowl fence. 30. Remove bolts at lower A-posts. 31. Remove instrument panel frame and wiring. 32. Remove bolts securing Heater-A/C housing to cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6174 INSTALLATION To install, reverse removal procedure. Verify that the cables are properly adjusted, free of interference and the control module is seated properly. CABLE ADJUSTMENT The cables must be adjusted for proper function of the control module. To adjust the cable: Attach the cable to the lever arm of the control module. - Turn the knob fully counterclockwise. - Pull the cable jacket away from the cable end until taut. - Clip the cable jacket to the control module. The knob should travel a full 180° if the cable is properly adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6175 Housing Assembly HVAC: Service and Repair Heater-A/C Housing Disassembly and Assembly Fig 74 Heater-A/C Unit Fig 75 Mode Motor Linkage UNIT HOUSING RECONDITION NOTE: Heater-A/C housing must be removed from vehicle before performing this operation. The heater a/c unit need not be disassembled to replace the heater core. Refer to: "Heater Core : Service and Repair" See: Heater Core/Service and Repair DISASSEMBLE 1. Place Heater-A/C unit assembly on workbench. Fig 76 Mode Motor 2. Remove A/C mode motor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6176 Fig 77 Recirculation Air Inlet Fig 78 Recirculation Housing Removal 3. Remove upper recirculation air inlet housing. Fig 79 Rear Y-Cam Release 4. From inside of air inlet, depress release tang on rear inlet door. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6177 Fig 80 Rear Y-Cam Actuator 5. Remove rear Y-cam actuator lever. 6. Turn front toggle lever until it lines up with slots on housing. 7. Pull straight up on toggle lever and slide toggle lever from underneath front actuator lever. 8. Remove front toggle lever. 9. Remove Y-cam rear lever. Fig 81 Rear Air Inlet Door 10. Unsnap and remove rear air inlet door. 11. Front air inlet door and lever is serviced with recirculation housing. Fig 82 Blower Motor Wiring 12. Remove blower motor wiring at resistor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6178 Fig 83 Blower Motor 13. Remove blower motor. Fig 84 Evaporator Probe 14. Using a flat blade pry tool, Pull up on tab at evaporator probe cover. turn evaporator probe cover clockwise 90°. Fig 85 Evaporator Probe Needle 15. Remove evaporator probe cover. Pull evaporator needle from evaporator. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6179 Fig 86 Blower Motor Resistor 16. Remove blower motor resistor. Fig 87 Housing Clips 17. Remove clips retaining evaporator housing to heater/distribution housing. Fig 88 Separate Housings 18. Separate evaporator housing from heater/distribution housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6180 Fig 89 Evaporator Tube Inlet Seal 19. Remove seal around evaporator tube inlet. Fig 90 Evaporator Housing Upper Cover 20. Remove evaporator housing upper cover. Fig 91 Remove Evaporator From Housing 21. Lift evaporator out of lower housing. 22. Remove styrofoam seal around evaporator. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6181 Fig 92 Lower Floor Distribution Housing 23. Remove lower heat/distribution housing clips. Remove housing. Fig 93 Heater Core Cover Fig 94 Heater Core Cover Removal 24. Remove heater core cover. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6182 Fig 95 Slide Out Core 25. Slide heater core out of heater housing. Fig 96 Temperature Door Lever Link 26. Remove temperature door lever link retaining screw. Fig 97 Temperature Door Lever Link Removal 27. Remove temperature door lever link. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6183 Fig 98 Floor Door Gear 28. From the panel door air opening, using a long thin screwdriver, push in clip for floor door gear. Remove floor door gear. Fig 99 Align Slots Fig 100 Remove Lever Link 29. Turn floor door lever link until it aligns with slots cut into it. Remove floor door lever link. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6184 Fig 101 Mode Motor Cam Fig 102 Mode Motor Cam Removal 30. Remove mode motor cam from housing. Fig 103 Panel Door Gear Release 31. From panel door access, using a long thin screwdriver, push in release tang on panel door gear. 32. Remove panel door gear from housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6185 Fig 104 Panel Door Lever Link 33. Line up slots on panel door lever link. Remove panel door lever link from housing. Fig 105 Defrost Door Lever Link 34. Unsnap defrost door lever link from housing. 35. Remove defrost door seal from housing. Fig 106 Front And Rear Housing Halves 36. Remove A/C housing rear cover half from front half. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6186 Fig 107 Defrost Door Removal 37. Remove defrost door from housing. Fig 108 Temperature Control Door Removal 38. Depress retaining clip at temperature control door, remove temperature control door. 39. Unsnap panel door from rear half of housing. Remove door from housing. Fig 109 Floor Door Removal 40. Unsnap floor door from front half of housing. Remove door from housing. ASSEMBLE 1. Install floor, panel, temperature, and defrost doors in housings. 2. Position front A/C housing half to rear half. Install retaining screws. 3. Install defrost door seal. 4. Snap defrost door lever link to door. 5. Install panel door lever link. Install panel door lever gear. 6. Install mode motor cam. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6187 7. Install floor door lever link. 8. Install floor door lever gear. 9. Install temperature door lever gear. 10. Install temperature door lever link. 11. Slide heater core into housing. Install cover. 12. Install lower distribution housing and clips. 13. Install styrofoam to evaporator. Install evaporator into the evaporator housing. 14. Install upper cover to evaporator housing. 15. Install seal around evaporator tube inlet. 16. Install evaporator probe into evaporator and housing. 17. Install blower motor and resistor. 18. Install air inlet housing to evaporator housing. 19. Install evaporator housing to heat/distribution housing. 20. Install mode motor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6188 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation NOTE: The heater core may be removed without removing the unit housing. Refer to: "Heater Core : Service and Repair" See: Heater Core/Service and Repair WARNINGS: - Avoid breathing a/c refrigerant and lubricant vapor or mist exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to reclaim R-134a systems. If accidental system discharge occurs, ventilate work area before resuming service. - R-134a service equipment or vehicle a/c system should not be pressure tested or leak tested with compressed air. Some mixtures of air and R-l34a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. REMOVAL 1. Disconnect battery negative remote cable. This must be done to prevent accidental air bag deployment. 2. Using an A/C recovery unit, remove all R-134a refrigerant from the A/C system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 3. Remove air cleaner hose and air distribution duct from the engine. 4. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair NOTE: The upper intake manifold has to be removed at this time to access the heater hose connections at the bulkhead. 5. Disconnect heater hoses at the dash panel. Plug the heater core inlet and outlet tubes to prevent antifreeze from spilling on the vehicle interior during removal. If an appropriate plug cannot be found pull back carpet and use caution when removing unit. Keep the heater tubes elevated to prevent spillage of coolant. 6. Remove both A/C lines from expansion valve. Use Special Tool Kit 7193 to disconnect quick connectors on A/C lines. After removing lines cap the expansion valve openings and the A/C hose openings. This will prevent any dirt or moisture from entering the refrigerant system during servicing. CAUTION: The lubricant used in this air conditioning system absorbs moisture readily (similar to brake fluid). Do not leave any portion of the system open for extended periods of time. Fig 66 Trim Bezel 7. Remove trim bezel. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6189 Fig 67 Control Module Screws 8. Remove cluster hood bezel retaining screws in the trim bezel opening. 9. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws. 10. Remove the cubby bin/cigar lighter bezel and wiring. 11. Remove the control module retaining screws. Fig 68 Control Module At Bezel Opening 12. Drop the A/C control module into the cigar lighter/cubby bin bezel opening. Then disconnect the wiring on the rear of the control module. 13. Release the cable clips from the top of the control module. Retain the clips for future use. Then disconnect the temperature control and recirculation control cables. 14. Remove the control module. 15. Remove upper instrument panel bezel. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 16. Remove right and left instrument panel end caps. 17. Remove left lower knee bolster. Disconnect mode door motor wiring. 18. Remove right and left interior door post kick panel. 19. Remove front and rear halves of floor console. 20. Remove the radio. 21. Remove right side lower silencer/duct. 22. Remove glove box assembly 23. Remove right side vertical Support strut brace. 24. Remove left side vertical support strut brace. 25. Remove center lower distribution housing. 26. Remove bolts securing Heater-A/C housing to metal I/P frame. 27. Remove upper instrument panel cowl trim cover. 28. Disconnect steering column from instrument panel. Lower steering column. 29. Remove instrument panel bolts at cowl fence. 30. Remove bolts at lower A-posts. 31. Remove instrument panel frame and wiring. 32. Remove bolts securing Heater-A/C housing to cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Removal and Installation > Page 6190 INSTALLATION To install, reverse removal procedure. Verify that the cables are properly adjusted, free of interference and the control module is seated properly. CABLE ADJUSTMENT The cables must be adjusted for proper function of the control module. To adjust the cable: Attach the cable to the lever arm of the control module. - Turn the knob fully counterclockwise. - Pull the cable jacket away from the cable end until taut. - Clip the cable jacket to the control module. The knob should travel a full 180° if the cable is properly adjusted. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications Receiver Dryer: Specifications Refrigerant Oil Capacity 30 ml (1 oz) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 6194 Receiver Dryer: Description and Operation Fig 51 Filter/Drier Location PURPOSE The drier is used to remove any traces of moisture from the refrigerant system. The filter is used to separate any foreign particles. OPERATION The filter/drier is a receiver for reserve refrigerant. It also has a desiccant bag and a filter. This is used to absorb moisture and filter the refrigerant as it passes through the filter/drier. The filter/drier is located left of the coolant bottle. The A/C refrigerant must be removed from the system before removing the filter/drier Always use a refrigerant recovery machine. Replace the filter/drier if an A/C system is left open for an extended period of time. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 6195 Receiver Dryer: Service and Repair Fig 51 Filter/Drier Location NOTES: - The filter/drier is a receiver for reserve refrigerant. It also has a desiccant bag and a filter. This is used to absorb moisture and filter the refrigerant as it passes through the filter/drier. - The filter/drier is located left of the coolant bottle. The A/C refrigerant must be removed from the system before removing the filter/drier Always use a refrigerant recovery machine. - Replace the filter/drier if an A/C system is left open for an extended period of time. REMOVAL 1. Remove refrigerant from A/C system using a refrigerant recovery machine. Fig 52 Liquid Line From Condenser 2. Remove liquid line at filter/drier from condenser. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 6196 Fig 53 Liquid Line From Expansion Valve 3. Remove liquid line at filter/drier from expansion valve. Fig 54 Receiver/Drier Bracket 4. Remove filter/drier bracket bolt at base of filter/drier. 5. Cap liquid line and condenser threaded fitting while system is open to prevent moisture from entering system. CAUTION: When installing new filter/drier do not leave open to atmosphere for a long period of time. The filter/drier contains moisture absorbing materials which will absorb moisture in the atmosphere. INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C Refrigerant/Oil - Capacity Revisions Refrigerant: Technical Service Bulletins A/C Refrigerant/Oil - Capacity Revisions NO: 24-19-96 GROUP: Air Conditioning DATE: Nov. 22, 1996 SUBJECT: A/C Performance MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus DISCUSSION: The type and quantity of refrigerant oil used in JA vehicles has been changed to enhance performance. The oil capacity of the total air conditioning system has been reduced to 5.0 ft. oz. (150 ml.) from 7.0 fl.oz. The oil designated for JA vehicles is SP-15 PAG (revised from SP-10), P/N 04886129AA. Following procedures/guidelines will maximize A/C system performance during routine service and diagnosing complaints of poor A/C performance. System Refrigerant Charge: ^ 1995-1996 vehicles, charge to 28 fl.oz. ^ 1997 vehicles, charge to 26 fl.oz. ^ All vehicles: To obtain the proper system refrigerant charge level using reclaim/recycling equipment, add an additional 2 fl.oz. of refrigerant per charging hose to account for charging hose capacity. Reference SUN STAND owners manual section "USING THE AUTO SEQUENCE FEATURE" (or equivalent). ^ The recommended procedure to check charge level is the "Partial Charge Test" (using the DRB III and a thermocouple). System Oil Level: ^ For vehicles built before April 1, 1996 (MDH 04-01-XX), remove 2.0 fl.oz. of oil from compressor. ^ For vehicle built after April 1, 1996 (MDH 04-01-XX), do not remove 2.0 fl.oz. of oil from compressor. ^ During routine service, use only SP-15 PAG refrigerant oil, Mopar P/N 04886129AA. 2.5L Engine Equipped Vehicles: ^ TSB 24-07-96 Rev. A should be performed on all 2.5L equipped vehicles with A/C performance complaints. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Capacity ................................................................................................................................... ......................................... 0.79 kg (28 oz or 1.75 lbs) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6203 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6204 Refrigerant: Description and Operation REFRIGERANT The R-134a refrigerant used in this air conditioning system is a non-toxic, non-flammable, clear, and colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to a R-134a refrigerant system, will cause compressor failure, refrigerant oil sludge, or poor air conditioning system performance. The refrigerant system service ports have been designed to ensure that the system is not accidentally filled with the wrong refrigerant (R-12). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Refrigerant/Oil - Capacity Revisions Refrigerant Oil: Technical Service Bulletins A/C Refrigerant/Oil - Capacity Revisions NO: 24-19-96 GROUP: Air Conditioning DATE: Nov. 22, 1996 SUBJECT: A/C Performance MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus DISCUSSION: The type and quantity of refrigerant oil used in JA vehicles has been changed to enhance performance. The oil capacity of the total air conditioning system has been reduced to 5.0 ft. oz. (150 ml.) from 7.0 fl.oz. The oil designated for JA vehicles is SP-15 PAG (revised from SP-10), P/N 04886129AA. Following procedures/guidelines will maximize A/C system performance during routine service and diagnosing complaints of poor A/C performance. System Refrigerant Charge: ^ 1995-1996 vehicles, charge to 28 fl.oz. ^ 1997 vehicles, charge to 26 fl.oz. ^ All vehicles: To obtain the proper system refrigerant charge level using reclaim/recycling equipment, add an additional 2 fl.oz. of refrigerant per charging hose to account for charging hose capacity. Reference SUN STAND owners manual section "USING THE AUTO SEQUENCE FEATURE" (or equivalent). ^ The recommended procedure to check charge level is the "Partial Charge Test" (using the DRB III and a thermocouple). System Oil Level: ^ For vehicles built before April 1, 1996 (MDH 04-01-XX), remove 2.0 fl.oz. of oil from compressor. ^ For vehicle built after April 1, 1996 (MDH 04-01-XX), do not remove 2.0 fl.oz. of oil from compressor. ^ During routine service, use only SP-15 PAG refrigerant oil, Mopar P/N 04886129AA. 2.5L Engine Equipped Vehicles: ^ TSB 24-07-96 Rev. A should be performed on all 2.5L equipped vehicles with A/C performance complaints. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ .......................................................... 150 ml. 5.00 oz. Condenser ........................................................................................................................................... ............................................................. 30 ml. 1.00 oz. Evaporator ........................................................................................................................................... ............................................................ 59 ml. 2.00 oz. Filter/Drier ............................................................................................................................................ .......................................................... 30 ml. 1.00 oz. A/C Lines ............................................................................................................................................. ........................................................... 44 ml. 1.50 oz. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6211 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. ......................................................................... SP-15 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6212 Refrigerant Oil: Service and Repair Refrigerant Oil Capacities SYSTEM OIL LEVEL It is important to have the correct amount of lubricant in the A/C system to ensure proper lubrication of the compressor. Too little lubricant will result in damage to the compressor. Too much lubricant will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. The lubricant used in the compressor is polyalkalene glycol PAG lubricant. Only refrigerant lubricant approved for use with R-134a should be used to service the system. Do not use any other lubricant. The lubricant container should be kept tightly capped until it is ready for use. Refrigerant lubricant will quickly absorb any moisture it comes in contact with. It is not necessary to check or add lubricant unless it has been lost. Lubricant loss at the leak point will be evident by the presence of a wet, shiny surface around the leak. REFRIGERANT OIL LEVEL CHECK When an air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with (R-134a) refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and receiver/drier will retain a significant amount of oil. Refer to the A/C Component Refrigerant Oil Capacities chart. 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 receiver/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 an A/C system the evaporator retains 60 ml. (2 oz.). The condenser retains 30 ml. (1 oz.) of oil, and system capacity may be 150 ml. (5.00 oz.) of oil. 150 ml. minus 90 ml. equals 60 ml. (2.00 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 SP15 PAG (polyalkalene glycol). VERIFY REFRIGERANT LUBRICANT LEVEL 1. Discharge refrigerant system using a recycling/ reclaiming equipment if a charge is present. 2. Disconnect refrigerant lines from A/C compressor Cap the open lines to prevent moisture from entering system. 3. Remove compressor from vehicle. 4. From suction and discharge ports on top of compressor, drain lubricant from compressor. 5. Add system capacity minus the capacity of components that have not been replaced. Refer to the A/C Component Refrigerant Oil Capacities chart above. Add lubricant through the suction and discharge ports on compressor. This is not to exceed 150 ml. (5.00 oz.) in total. 6. Install compressor and connect refrigerant lines. Then evacuate and charge refrigerant system. 7. Most reclaim/recycling equipment will measure the lubricant being removed. This is the amount of lubricant to be added back to the system. If a new compressor is being installed, drain lubricant from old compressor, measure the amount drained and discard old lubricant. Drain the lubricant from the new compressor into a clean container. Return the amount of lubricant measured from the old compressor, plus the amount reclaimed from the system back into the new compressor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Fig 12 Pressure Transducer The pressure transducer is screwed attached to a valve on the discharge line near the compressor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6216 Refrigerant Pressure Sensor / Switch: Description and Operation Fig 11 Pressure Transducer - Viewed From Beneath Vehicle Fig 12 Pressure Transducer The A/C Pressure Transducer functions as the refrigerant system pressure sensor. It supports the condenser/radiator fans and compressor functions. The pressure transducer is attached to a valve on the discharge line near the compressor. Circuit C18 connects from the Powertrain Control Module (PCM), cavity 42, to the transducer. The PCM uses information from the transducer to control operation of the radiator fans. Ground for the transducer is supplied on circuit K4. This circuit connects to cavity 43 of the PCM connector. The K4 circuit is spliced in with many of the sensors used in the fuel injection and ignition systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6217 Refrigerant Pressure Sensor / Switch: Service and Repair Fig 12 Pressure Transducer CAUTION: A/C pressure transducer switch connector terminal contacts can be damaged by probing tools during system diagnosis and repair. Failure to use their respective mating terminals or pin gauge to check for tightness will cause contact beam spreads. This will result in loss of continuity. NOTE: O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for this vehicle. REMOVAL 1. Disconnect the wire harness connector from the A/C pressure transducer. NOTE: A slight release of pressure trapped in the fitting may be experienced. It is not necessary to discharge the refrigerant system. 2. Remove the transducer with a counterclockwise rotation using a 14 mm open-end wrench. INSTALLATION For installation, reverse above procedures. Tighten pressure transducer to 6 Nm (50 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 This system uses no blower motor relay. Motor is controlled by the fan control switch in the heater control head and by the blower motor resistor block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution Center Relay is in the Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation Control Module HVAC: Description and Operation SYSTEM OPERATION HVAC Control Module HVAC Control Module The rear window control switch and circuit are integrated into the HVAC control module. When actuating the switch it sends a ground signal to the Body Control Module (BCM). The BCM actuates the relay allowing current to flow through the grid lines for ten minutes upon initial actuation. Then 5 minutes with each subsequent actuation or until either the switch or ignition is turned off. An indicating lamp illuminates the rear window defogger switch. CIRCUIT OPERATION A/C - Heater Control The air conditioning-heater system is controlled by the Body Control Module (BCM). The BCM sends out voltage to the A/C-Heater control on circuit C58. The control uses resistors to internal to the control. These resistors are connected to the Z2 ground circuit. When the operator requests a function in the system the BCM measures the voltage drop, on circuit C58, and activates the mode actuator door to the proper position. A separate A/C switch is used in the system. This switch works the same as the mode actuator switches. When the operator presses the switch the BCM measures the voltage drop in the C21 circuit and activates the proper functions. Internal to the A/C-Heater control the A/C switch is connected to the blower motor switch. This allows the A/C system to only operate when the blower switch in an ON position. Ground for the A/C switch is provided through the blower motor switch to the Z1 circuit. This circuit terminates at the instrument panel left side cowl. A Light Emitting Diode (LED) is connected in the C21 circuit and illuminates when the A/C system is operating. Illumination lamps and LED's are internal to the control. These are controlled by the BCM. The E2 circuit from the BCM provides the voltage to the control for lamp and LED illumination. Ground for the lamps and LED's is provided on the Z1 circuit which terminates at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Page 6228 Control Module HVAC: Service and Repair Fig 29 Control Module NOTE: The control module is located below the radio. REMOVAL 1. Place the ignition key in the OFF position before removing control module. 2. Remove trim bezel. Fig 30 Control Module Screws 3. Remove cluster hood bezel retaining screws in the trim bezel opening. 4. Pry up the cluster hood bezel a few inches to expose the cubby bin/cigar lighter bezel screws. 5. Remove the cubby bin/cigar lighter bezel and wiring. 6. Remove the control module retaining screws. Fig 31 Control Module At Bezel Opening Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Page 6229 7. Drop the A/C control module into the cigar lighter/cubby bin bezel opening. Then disconnect the wiring on the rear of the control module. 8. Release the cable clips from the top of the control module. Retain the clips for future use. Then disconnect the temperature control and recirculation control cables. 9. Remove the control module. INSTALLATION For installation reverse the above procedures. Verify that the cables are properly adjusted and the module is seated properly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Circuit Information Evaporator Probe: Description and Operation Circuit Information CIRCUIT OPERATION A/C Evaporator Temperature Sensor The A/C evaporator temperature sensor, located in the A/C-Heater housing, provides the Body Control Module (BCM) with the evaporator temperature to prevent the evaporator from freezing. Power for the sensor is provided from the BCM to the sensor on circuit C12. The ground for the sensor is on circuit C57 to the BCM. Information on evaporator temperature is sent to the Powertrain Control Module (PCM) across the CCD Bus. The PCM uses this information to control operation of the A/C compressor clutch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Circuit Information > Page 6236 Evaporator Probe: Description and Operation Evaporator Temperature Sensor EVAPORATOR PROBE The evaporator temperature probe prevents condensate water on the evaporator coil from freezing and obstructing A/C system air flow It does this by cycling the compressor clutch on and off. The switch is attached to the evaporator coil with the sensing probe inserted into the coil fins. The evaporator probe is a temperature sensing element located at the coldest point on the face of the evaporator. Output from the probe is sampled by the Body Control Module (BCM). It is used to switch the A/C compressor clutch OFF before evaporator freeze up occurs. The clutch is switched OFF when the probe temperature reaches O.94°C. (33.7°F.). It is allowed to switch ON when the probe temperature reaches 2.05°C. (35.7°F). The evaporator probe is located on the lower right side of the evaporator housing. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Page 6237 Evaporator Probe: Service and Repair Fig 41 Evaporator Probe Wiring REMOVAL 1. Disconnect battery. 2. Remove right under panel silencer/duct. 3. Disconnect wiring connector for evaporator probe. Fig 42 Evaporator Probe 4. Using a flat blade pry tool pull back on the locking tab. Twist the access plate clockwise one quarter turn and remove plate. Fig 43 Remove Probe 5. Pull probe out of evaporator core. This plate must be pushed inside the A/C unit and orientated in such a way that the plate can be removed. INSTALLATION 1. Install new probe into the evaporator. The new probe must not go into the same hole (in the evaporator core) that the old probe was removed. The evaporator is manufactured with three holes for probe insertion. Insert the probe in the uppermost hole. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Probe <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation > Page 6238 2. Install evaporator probe access panel. 3. Connect probe wiring harness. 4. Reconnect battery. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Fig 12 Pressure Transducer The pressure transducer is screwed attached to a valve on the discharge line near the compressor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6242 Refrigerant Pressure Sensor / Switch: Description and Operation Fig 11 Pressure Transducer - Viewed From Beneath Vehicle Fig 12 Pressure Transducer The A/C Pressure Transducer functions as the refrigerant system pressure sensor. It supports the condenser/radiator fans and compressor functions. The pressure transducer is attached to a valve on the discharge line near the compressor. Circuit C18 connects from the Powertrain Control Module (PCM), cavity 42, to the transducer. The PCM uses information from the transducer to control operation of the radiator fans. Ground for the transducer is supplied on circuit K4. This circuit connects to cavity 43 of the PCM connector. The K4 circuit is spliced in with many of the sensors used in the fuel injection and ignition systems. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6243 Refrigerant Pressure Sensor / Switch: Service and Repair Fig 12 Pressure Transducer CAUTION: A/C pressure transducer switch connector terminal contacts can be damaged by probing tools during system diagnosis and repair. Failure to use their respective mating terminals or pin gauge to check for tightness will cause contact beam spreads. This will result in loss of continuity. NOTE: O-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the O-ring specified for this vehicle. REMOVAL 1. Disconnect the wire harness connector from the A/C pressure transducer. NOTE: A slight release of pressure trapped in the fitting may be experienced. It is not necessary to discharge the refrigerant system. 2. Remove the transducer with a counterclockwise rotation using a 14 mm open-end wrench. INSTALLATION For installation, reverse above procedures. Tighten pressure transducer to 6 Nm (50 in lb). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation The refrigerant system service ports are used to charge,recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port fitting sizes are used on the R-134a system, to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment. The high pressure gauge port is located on the compressor discharge line. The low pressure gauge port is located on the suction line. After servicing the refrigerant system, always reinstall the service port caps. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Specifications Thermal Limiter Switch: Specifications Cut OFF Temperature .............................................................................................................................................................. 122 to 128°C (252 to 262°F) Cut IN Temperature ............................................................................... .................................................................................. 104 to 116°C (225 to 235°F) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Specifications > Page 6250 Thermal Limiter Switch: Description and Operation The switch is used to measure compressor surface temperature. If compressor surface temperature is excessive the switch will cut battery feed voltage to the compressor clutch. The switch will then reset once compressor surface temperature returns to normal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Specifications > Page 6251 Thermal Limiter Switch: Testing and Inspection THERMAL LIMITER SWITCH 1. Unplug Thermal Limiter wiring connector. 2. With an ohmmeter check for continuity between the two terminals. If no continuity is present replace switch. 3. The Thermal Limiter is calibrated to open and close at: - Open circuit (no continuity at 122 to 128°C (252 to 262°F). - Close circuit (continuity) at 106 to 116°C (225 to 235°F). NOTE: There is no serviceability of the thermal limiter switch. If the thermal limiter switch fails, the compressor must be replaced. To replace the compressor, refer to Compressor Service and Repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Specifications > Page 6252 Thermal Limiter Switch: Service and Repair There is no serviceability of the thermal limiter switch. If the thermal limiter switch fails, the compressor must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6258 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. ARMING 1. Connect battery ground cable. 2. From PASSENGER side of vehicle, turn ignition switch to ON position. 3. The SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 4. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Air Bag: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 6263 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 6264 Air Bag: Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 6265 Air Bag: Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Customer Safety Information > Page 6268 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions > Page 6269 Air Bag: Description and Operation WARNING: Never disassemble the driver or passenger airbag module, there are no serviceable parts within the module. DESCRIPTION It contains the airbag cushion and its supporting components. The airbag module contains a housing in which the cushion and inflator are attached and sealed. OPERATION The driver side inflator assembly is mounted from the back of the module housing. When supplied with the proper electrical signal, the inflator assembly produces a gas and discharges it directly into the cushion. A protective cover is fitted to the front of the Driver Airbag Module and forms a decorative cover in the center of the steering wheel. The Driver Air-bag Module is mounted directly to the steering wheel. The passenger inflator assembly is within the module housing. The module is mounted to the instrument panel retainer and support structure. When supplied with the proper electrical signal the inflator will produce a gas and discharge it directly into the cushion. A protective cover is fitted into the instrument panel over the airbag module and forms a decorative cover. The Passenger Airbag (PAB) Module consists: ^ Inflator assembly ^ Reaction canister ^ Airbag Pillow ^ Deployment door The PAB module is mounted to the instrument panel plastic retainer and steel reinforcement assembly. When supplied with the proper electrical signal, the inflator produces gas and discharges it directly into the pillow. The deployment door will hinge, allowing the pillow to fully inflate. LOCATION The Driver Airbag Module located in the center of the steering wheel is the most visible part of the system. The Passenger Airbag Module is located beneath the decorative cover of the instrument panel, facing the passenger seat. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 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, adhered to air bag module, material that could irritate eyes and/or skin. Note: If any irritation develops, seek medical attention. 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. CAUTION: 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 described under 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 6272 Air Bag: Service and Repair Driver Side Airbag Module Replacement REMOVAL WARNING: When removing a deployed Driver Airbag Module, rubber gloves, eye protection and long sleeves should be worn. There may be deposits on the surface that could irritate the skin and eyes. 1. Disconnect and isolate the battery negative remote cable. 2. Remove the Driver Airbag Module attaching T-30 Torx bolts from back side of the steering wheel. Lift the module and disconnect the wire by: a. Lifting the secondary latch. b. Disconnect the connector from back of the Driver Airbag Module using the finger grips. Use care not to pull on wires. Never use a metallic tool to pry off the connector. 3. Remove the speed control switch screws from the back of the steering wheel. Pull the switch pods out and disconnect the wires. 4. Disconnect the horn wire from the airbag mounting bracket. Remove the speed control wires from the wire guides. 5. When replacing a deployed Driver Airbag Module, the clockspring must also be replaced. Refer to Clockspring Assembly/Spiral Cable/Service and Repair for the proper procedure. INSTALLATION 1. Connect horn wire to the Driver Airbag Module mounting bracket. Connector Driver Airbag Module connector to the back of the module. Make airbag connection by pressing straight in on the connector. The connector should be fully seated to ensure a positive connection. Ensure that the wires do not get pinched during installation. 2. Install the two module bolts and tighten to 9 to 10 N.m (80 to 90 in. lbs.) torque. 3. Connect wire connectors to the speed control switches and install the switches. Tighten the screws to 0.7 to 2.7 N.m (6 to 24 in lbs.). Do not connect battery negative remote cable. Refer to Testing and Inspection/Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 6273 Air Bag: Service and Repair Passenger Side Airbag Module Replacement Deployed Module NOTE: When removing a deployed Passenger Airbag Module: ^ Rubber gloves ^ Eye protection ^ Long sleeves should be worn. There may be deposits on the surface which could irritate the skin and eyes. REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Open both vehicle front doors. Remove left end cover by pulling outboard. Remove right end cover by pulling rearward. 3. Remove the transmission range indicator bezel from floor console. Use care not to mar the bezel or console. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 6274 4. Remove the floor center console. Remove two mounting screws in the front and two mounting screws under the decorative caps in the rear. 5. Disconnect Airbag Control Module (ACM). 6. Remove the instrument cluster hood. a. Remove two screws along side of the radio. b. Remove two screws below the HVAC control. c. Remove the screw at left end of the panel. d. Pull hood rearward to disengage the eight clips. 7. Remove two cubby bin screws and remove. 8. Remove five knee blocker mounting screws. 9. Open glove box door and press the sidewalls inboard to lower door from panel to access forward floor console. 10. Remove the forward floor console nine attaching screws and one push pin at forward driver's side. 11. Pull the driver's under panel silencer outboard off the distribution duct. 12. Remove the instrument panel top cover attaching screw on passenger side. a. Starting from right to the left side. Lift the right rear edge of top cover to disengage the clips along the rear edge. Do not use a nylon trim stick, to avoid marring cover or panel. b. Lift rear edge and pull the top cover rearward disengaging clips and remove cover. 13. Remove the HVAC control attaching screws. 14. Remove the radio. Access and remove the three HVAC attaching screws to duct and panel. Remove the three HVAC attaching bolts from the cross-car beam. 15. Close the glove box door. 16. Remove five screws attaching panel retainer to plenum. 17. Remove the steering column attaching bolts. 18. Disconnect the engine and body wire harness from Junction Block/BCM. 19. Remove the fasteners: ^ Four at the left end and three at the right end of the cross car beam ^ Two at the steering column plenum ^ One at the glove box hinge to cowl ^ Two at the center support to the floor pan bracket 20. Lift up the instrument panel and move it rearward to remove. 21. After removal of the instrument panel disconnect Driver Airbag Module wire connector. 22. Remove the six Driver Airbag Module fasteners and remove the airbag module. INSTALLATION For installation, reverse the above procedures. 1. Remove all of the instrument panel components that are not damaged and replace any components that are damaged. 2. Use a new instrument panel pad. 3. Install all of the components. 4. Install a new Passenger Airbag Module and tighten nuts to 11 N.m (100 in. lbs.) and screws to 2 N.m (20 in. lbs.) torque. Do not connect battery negative remote cable. Refer to Testing and Inspection/Procedures. Undeployed Module REMOVAL When removing a module for any reason other than DEPLOYMENT. 1. Disconnect and isolate the battery negative remote cable. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 6275 2. Open and lower glove box fully to gain access to Passenger Airbag Module (PAB) attaching screws inside of the glove box. Glove box removal not required. 3. Disconnect wire connector from the Passenger Airbag Module. 4. Remove the four nuts and two screws attaching airbag assembly to the instrument panel collar. 5. Lift Passenger Airbag Module up and out of panel cavity INSTALLATION For installation, reverse the above procedures. Install new Passenger Airbag Module and tighten nuts to 11 N.m (100 in. lbs.) and screws to 2 N.m (20 in. Lbs.) torque. Do not connect battery negative remote cable. Refer to Testing and Inspection/Procedures for Air-bag System Test procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Air Bag Control Module Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 6281 * = Wire With Tracer Stripe Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 6284 Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 6285 Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > General Information Air Bag Control Module: Description and Operation General Information DESCRIPTION The Airbag Control Module (ACM) contains the impact sensor, and a microprocessor that monitors the impact sensor and the airbag system electrical circuits to determine the system readiness. The ACM contains On-Board Diagnostics (OBD), and will send an airbag lamp-on message to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to light the airbag indicator lamp in the instrument cluster when a monitored airbag system fault occurs. OPERATION The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired and, if damaged or faulty, it must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > General Information > Page 6288 Air Bag Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Two different circuits supply battery voltage from the junction block to the Airbag Control Module (ACM), they are F14 and F23. The F14 and F23 circuits are connected to separate bus bars internal to the junction block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the junction block bus bars. The F23 circuit supplies battery voltage to the ACM only when the ignition switch is in the RUN position. The F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. A bus bar internal to the ignition switch connects the A1 circuit from the Power Distribution Center (PDC) to the A21 circuit when the switch is in either the START or RUN position. The A21 circuit supplies battery voltage to the junction block bus bar that feeds the F14 circuit. A 20 amp fuse in the PDC, cavity 8, protects the A1 and A21 circuits. A 10 amp fuse in cavity 17 of the unction block protects the F14 circuit. when the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the junction block bus bar that feeds the F23 circuit. A 40 amp fuse in cavity 16 of the PDC protects the A2 and A22 circuits. A 10 amp fuse in cavity 16 of the junction block protects the F23 circuit. The ACM has a case ground and an external dedicated ground, circuit Z2. The dedicated ground connects to the floor pan near the ACM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Page 6289 Air Bag Control Module: Service and Repair WARNING: Replace Airbag System components with Chrysler Mopar specified replacement parts. Substitute parts may visually appear interchangeable, but internal differences may result in inferior occupant protection. The ACM contains an impact sensor that enables the system to deploy the air-bags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Raise parking brake lever as high as possible. 3. Loosen set screw on front of shifter knob and remove shift lever knob. 4. Remove plastic plunger rod from shifter lever. 5. Remove lighted PRNDL letter bezel. 6. Remove screws next to floor shifter and in console storage compartment, holding floor console to the brackets on the floor pan. 7. Disconnect wire connector for floor console accessories at floor pan. 8. Separate console from vehicle. 9. Remove the park brake lever assembly. 10. Disconnect wire harness connector from the Airbag Control Module. 11. Remove four module mounting nuts and remove module. CAUTION: Use supplied nuts only. INSTALLATION 1. Install ACM, position ACM (arrow pointing forward) on center tunnel area mounting studs. Attach the two rear mounting nuts and tighten to 14 to 19 N.m (125 to 170 in. lbs.) torque. 2. Position console in vehicle. 3. Verify that the rear locator pin on the bottom of the storage bin is engaged to the slot in the body bracket. 4. Connect the wire connector for the floor console accessories at floor pan. 5. Install lighted PRNDL letter bezel. 6. Install plastic plunger rod to shifter lever. 7. Install shift lever knob and tighten set screw on front of shifter knob. 8. Do not connect battery negative remote cable. Refer to Testing and Inspection/Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6294 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6295 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6296 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6297 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6298 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6299 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6300 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (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 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (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. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6301 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6302 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6303 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6304 PARTS REQUIRED: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6305 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 on T.I.L. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6306 POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Restraint System - Air bag Clockspring Service Revision Clockspring Assembly / Spiral Cable: Technical Service Bulletins Restraint System - Air bag Clockspring Service Revision NUMBER: 26-12-96B GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Cirrus, Stratus & Breeze - Publication Number 81-270-7121 DESCRIPTION OF CHANGES Revision the Air Bag clock spring service procedure Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Restraint System - Air bag Clockspring Service Revision > Page 6311 8M-5 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Restraint System - Air bag Clockspring Service Revision > Page 6312 Clockspring Assembly / Spiral Cable: 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Restraint System - Air bag Clockspring Service Revision > Page 6313 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6314 Clockspring Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6315 Speed Control Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Customer Safety Information > Page 6318 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6319 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring is mounted to the steering column behind the steering wheel. The clockspring is used to maintain a continuous electrical circuit between the wiring harness and the: ^ Driver's airbag module ^ Speed control switches ^ Horn switch The clockspring consists of a flat, ribbon like, electrically conductive tape that winds and unwinds with the steering wheel rotation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6320 Clockspring Assembly / Spiral Cable: Adjustments CLOCKSPRING CENTERING PROCEDURE If the rotating tape within the clockspring is not positioned properly with the steering wheel and the front wheels, the clockspring may fail during use. The clockspring is centered when yellow appears in the centering window and the arrow on the rotor points to the window. If clockspring is not centered, the following procedure MUST BE USED to center the clockspring: 1. To center the clockspring, with steering wheel removed, depress the two plastic locking pins to disengage the mechanism. Rotate clockspring until yellow appears in the centering window. 2. The arrow on the rotor will be pointing at the window if the clockspring is centered. Release locking pins to engage locking mechanism. 3. For installation, refer to Service and Repair. Do not connect the battery negative remote cable. Refer to Testing and Inspection/Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6321 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL WARNING: When removing a deployed module, rubber gloves, eye protection and long sleeves should be worn. There may be deposits on the surface which could irritate the skin and eyes. 1. Disconnect and isolate the battery negative remote cable. 2. Remove the two steering column lower cover attaching screws. Remove upper cover. 3. Remove the Driver Airbag Module attaching T-30 Torx bolts from back side of the steering wheel. Lift the module and disconnect the wire by: a. Lifting the secondary latch. b. Disconnect the connector from back of the airbag module using the finger grips. Use care not to pull on wires. Never use a metallic tool to pry on the connector. 4. Remove the speed control switch screws from back of the steering wheel. Pull the switch pods out and disconnect the wires. 5. Disconnect the horn wire from the steering wheel and remove the speed control wires from the wire guides. 6. Remove the steering wheel. Carefully feed all wires through the steering wheel armature to avoid damaging wires. When replacing a deployed Driver Airbag Module, a new clockspring must be installed. 7. Remove the nut attaching steering wheel to the steering column. 8. Disconnect the natural 3-way and the yellow 2-way connectors from back side of the Driver Airbag Module. 9. Remove the steering column shrouds by unfastening the two fasteners. 10. Remove multi-function switch by unfastening the three screws. 11. Remove the clockspring by lifting the top lock housing latches up slightly to guide it over the lock housing. The clockspring cannot be serviced. INSTALLATION 1. Adjust the steering wheel so that the tires are straight ahead position. 2. Center the clockspring by ensuring the yellow indicator visually seen through the centering window. Refer to Clockspring Centering Procedure. 3. Align the top locking tab with the slot on the lock housing. Gently push into place. 4. Install the multi-function switch and tighten to 1.5 to 2.5 N.m (14 to 22 in. lbs.) torque. 5. Install the steering column shrouds and tighten to 1.7 to 2.3 N.m (15 to 20 in. lbs.) torque. 6. Carefully route the wires through the hole in the steering wheel armature. Install steering wheel and Tighten to 61 N.m (45 ft. lbs.) torque. 7. Route the speed control wires under the horn mechanism and through the speed control switch pockets. Connect the speed control wires to switches and install switches. Tighten screws to 0.7 to 2.7 N.m (6 to 24 in. lbs.) torque. 8. Connect horn lead to the airbag module mounting bracket. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 6322 9. Connect the yellow airbag lead to the Driver Airbag Module and push secondary latch into place. Ensure the wires do not get pinched during installation. 10. Install the airbag module bolts and tighten to 9 to 10 N.m (80 to 90 in. lbs.) torque. Do not connect the battery negative remote cable. Refer to Testing and Inspection/Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations Data Link Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations NOTE: The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 6331 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Page 6332 Impact Sensor: Description and Operation CIRCUIT OPERATION The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations Malfunction Lamp / Indicator: Locations The warning lamp is located in the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Circuit Operation Malfunction Lamp / Indicator: Description and Operation Circuit Operation CIRCUIT OPERATION Illumination of the Airbag warning lamp is controlled by the Body Control Module (BCM) and the CCD Bus. When the Airbag Control Module ( ACM) detects a problem in the system it sends a signal on the CCD Bus to the BCM. The BCM process the signal and illuminates the AIRBAG lamp in the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Circuit Operation > Page 6338 Malfunction Lamp / Indicator: Description and Operation Air Bag Warning Lamp 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Page 6339 Malfunction Lamp / Indicator: Testing and Inspection - Check for blown fuses in the circuits that connect to the ignition switch and in those that connect to the ACM - While the bus bars in the junction block power the ACM, they also feed additional components on separate fuse-protected circuits - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the floor pan near the ACM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors 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 - 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) 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 (WJ) 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 trucks 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 detailed instruction sheet. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6344 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6345 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6346 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6347 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6348 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector Air Bag Control Module Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Air Bag Control Module 4 Way Connector > Page 6355 * = Wire With Tracer Stripe Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 6358 Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Customer Safety Information > Page 6359 Air Bag 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > General Information Air Bag Control Module: Description and Operation General Information DESCRIPTION The Airbag Control Module (ACM) contains the impact sensor, and a microprocessor that monitors the impact sensor and the airbag system electrical circuits to determine the system readiness. The ACM contains On-Board Diagnostics (OBD), and will send an airbag lamp-on message to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to light the airbag indicator lamp in the instrument cluster when a monitored airbag system fault occurs. OPERATION The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired and, if damaged or faulty, it must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > General Information > Page 6362 Air Bag Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Two different circuits supply battery voltage from the junction block to the Airbag Control Module (ACM), they are F14 and F23. The F14 and F23 circuits are connected to separate bus bars internal to the junction block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the junction block bus bars. The F23 circuit supplies battery voltage to the ACM only when the ignition switch is in the RUN position. The F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. A bus bar internal to the ignition switch connects the A1 circuit from the Power Distribution Center (PDC) to the A21 circuit when the switch is in either the START or RUN position. The A21 circuit supplies battery voltage to the junction block bus bar that feeds the F14 circuit. A 20 amp fuse in the PDC, cavity 8, protects the A1 and A21 circuits. A 10 amp fuse in cavity 17 of the unction block protects the F14 circuit. when the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the junction block bus bar that feeds the F23 circuit. A 40 amp fuse in cavity 16 of the PDC protects the A2 and A22 circuits. A 10 amp fuse in cavity 16 of the junction block protects the F23 circuit. The ACM has a case ground and an external dedicated ground, circuit Z2. The dedicated ground connects to the floor pan near the ACM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Page 6363 Air Bag Control Module: Service and Repair WARNING: Replace Airbag System components with Chrysler Mopar specified replacement parts. Substitute parts may visually appear interchangeable, but internal differences may result in inferior occupant protection. The ACM contains an impact sensor that enables the system to deploy the air-bags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. REMOVAL 1. Disconnect and isolate the battery negative remote cable. 2. Raise parking brake lever as high as possible. 3. Loosen set screw on front of shifter knob and remove shift lever knob. 4. Remove plastic plunger rod from shifter lever. 5. Remove lighted PRNDL letter bezel. 6. Remove screws next to floor shifter and in console storage compartment, holding floor console to the brackets on the floor pan. 7. Disconnect wire connector for floor console accessories at floor pan. 8. Separate console from vehicle. 9. Remove the park brake lever assembly. 10. Disconnect wire harness connector from the Airbag Control Module. 11. Remove four module mounting nuts and remove module. CAUTION: Use supplied nuts only. INSTALLATION 1. Install ACM, position ACM (arrow pointing forward) on center tunnel area mounting studs. Attach the two rear mounting nuts and tighten to 14 to 19 N.m (125 to 170 in. lbs.) torque. 2. Position console in vehicle. 3. Verify that the rear locator pin on the bottom of the storage bin is engaged to the slot in the body bracket. 4. Connect the wire connector for the floor console accessories at floor pan. 5. Install lighted PRNDL letter bezel. 6. Install plastic plunger rod to shifter lever. 7. Install shift lever knob and tighten set screw on front of shifter knob. 8. Do not connect battery negative remote cable. Refer to Testing and Inspection/Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6368 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. ARMING 1. Connect battery ground cable. 2. From PASSENGER side of vehicle, turn ignition switch to ON position. 3. The SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 4. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6374 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6375 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6376 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6377 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6378 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6379 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6380 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6381 detailed instruction sheet. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6382 PARTS REQUIRED: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6383 POLICY: Customer Satisfaction Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6384 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6385 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors 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 - 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) 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 (WJ) 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 trucks 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 detailed instruction sheet. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6386 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6387 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6388 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6389 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6390 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service Seat Belt: Technical Service Bulletins Interior - Seat Belt Cinch Bar Service NUMBER: 08-010-03 GROUP: Electrical DATE: Apr.25, 2003 SUBJECT: Seat Belt Cinch Bar Service MODELS: 2001 - 2003 (AB) Ram Van/Wagon (Front Passenger Seat Belt Only) 1994 (BR) Ram Pickup 1996-2002 (BR/BE) Ram Pickup 2001 - 2003 (DN) Durango (Front Passenger Seat Belt Only) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 1996 - 2000 (JX) Sebring Convertible 1995 - 2003 (PL) Neon/SX 2.0 2001 - 2003 (PT) PT Cruiser DISCUSSION: Any time the seat belt cinch bar (Fig. 1) is loose, missing or damaged it is no longer necessary to replace the seat belt assembly. Cinch bar repair kits are now available for the vehicles listed. If any component of the seat belt assembly has been damaged due to collision, the entire assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 6395 NOTE: THE CINCH BAR, CINCH BAR COVER OR ANY OTHER COMPONENT OF THE SEAT BELT ASSEMBLY MUST NEVER BE PAINTED. NOTE: INSTALLATION INSTRUCTIONS ARE INCLUDED WITH EACH KIT. PARTS REQUIRED: NOTE: SELECT THE COLOR CLOSEST TO THE SEAT BELT ASSEMBLY COLOR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation CIRCUIT OPERATION Seat Belt Indicator The fasten seat belt indicator is used with the warning chime to tell the operator to fasten the seat belt. The seat belt switch is normally OPEN when the seat belt is buckled. If the seat belt is not buckled, the switch CLOSES, and a ground path is completed on the G10 circuit to the Z1 circuit. The G10 circuit is connected to the Body Control Module (BCM). When the ground path is complete a signal is sent over the CCD Bus to the instrument cluster. This illuminates the lamp in the instrument cluster. When the ignition switch is moved to the START position, the lamp is illuminated as a bulb check. Logic internal to the BCM determines the length of time the lamp remains illuminated. Seat Belt Warning The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch, located in the left B-Pillar, is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Body Control Module (BCM) and the switch. Ground for the switch is provided on circuit Z1. The Z1 circuit terminates at the deck lid ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6404 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6405 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6406 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6407 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6408 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6409 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6410 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (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 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (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. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6411 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6412 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6413 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6414 PARTS REQUIRED: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6415 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 on T.I.L. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6416 POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations NOTE: The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 6422 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 6423 Impact Sensor: Description and Operation CIRCUIT OPERATION The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Customer Interest for Antenna: > 08-02-98 > Jan > 98 > Antenna Mount - Broken/Loose Antenna: Customer Interest Antenna Mount - Broken/Loose NO: 08-02-98 GROUP: Electrical DATE: Jan. 23, 1998 SUBJECT: Antenna Mount Broken/Loose MODELS: 1997 - 1998 (JA) Breeze/Cirrus/Stratus DISCUSSION: To prevent antenna masts from becoming loose, a change was implemented in February 1997 to incorporate a torque prevailing feature on the antenna mast. This torque prevailing feature is an indentation on the antenna mast which causes a slight interference with the antenna body stud. For this reason, the antenna mast can only be hand tightened until it reaches the torque prevailing feature. At this point a torque wrench must be utilized to properly seat the antenna mast to the antenna body. During New Vehicle Prep or other antenna service a torque wrench with crows foot socket must be used to install the antenna mast. The antenna mast must be tightened to 25-30 in. lbs. NOTE: DO NOT EXCEED 30 IN. LBS. OF TORQUE TO SEAT THE ANTENNA MAST. EXCESSIVE TORQUE WILL BREAK/LOOSEN THE ANTENNA MOUNT. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna: > 08-02-98 > Jan > 98 > Antenna Mount - Broken/Loose Antenna: All Technical Service Bulletins Antenna Mount - Broken/Loose NO: 08-02-98 GROUP: Electrical DATE: Jan. 23, 1998 SUBJECT: Antenna Mount Broken/Loose MODELS: 1997 - 1998 (JA) Breeze/Cirrus/Stratus DISCUSSION: To prevent antenna masts from becoming loose, a change was implemented in February 1997 to incorporate a torque prevailing feature on the antenna mast. This torque prevailing feature is an indentation on the antenna mast which causes a slight interference with the antenna body stud. For this reason, the antenna mast can only be hand tightened until it reaches the torque prevailing feature. At this point a torque wrench must be utilized to properly seat the antenna mast to the antenna body. During New Vehicle Prep or other antenna service a torque wrench with crows foot socket must be used to install the antenna mast. The antenna mast must be tightened to 25-30 in. lbs. NOTE: DO NOT EXCEED 30 IN. LBS. OF TORQUE TO SEAT THE ANTENNA MAST. EXCESSIVE TORQUE WILL BREAK/LOOSEN THE ANTENNA MOUNT. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Page 6438 Antenna: Description and Operation SYSTEM OPERATION The power operated radio antenna is a telescoping type antenna, extended and retracted by a reversible electric motor. The Automatic Power Antenna is controlled by a combination of an internal relay and limit switches which, are built into the antenna motor housing. This antenna is actuated when the radio is switched ON and the ignition switch in ON or ACCESSORY position. When the ignition switch or the radio is turned OFF the antenna mast should retract fully. Many antenna problems may be avoided by frequent cleaning of the antenna mast telescoping sections. Clean the antenna mast sections with a clean soft cloth. Before an antenna is removed, the antenna performance should be tested to decide if it is a reception problem or an operational problem. Whenever a operational malfunction occurs, first verify that the radio antenna wire harness is properly connected. Check all connectors before starting normal diagnosis and repair procedures Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Testing and Inspection > Manual Antenna Antenna: Testing and Inspection Manual Antenna Check for short or open circuits with an ohmmeter or continuity light once the antenna cable is disconnected from the radio. The radio coax cable has a connector that connects behind the between passenger seat and console. Antenna Test Points 1. Continuity should be present between the antenna mast and radio end pin of antenna cable plug. 2. No continuity should be observed or a very high resistance of several megohms between the ground shell of the connector and radio end pin. 3. Continuity should be observed between the ground shell of the connector and the mounting hardware in the trunk right rear quarter panel. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Testing and Inspection > Manual Antenna > Page 6441 Antenna: Testing and Inspection Power Antenna Power Antenna Assembly 1. To extend antenna, using jumper wires, attach one end to a battery positive source and the other to the red and green wire terminals for up direction. Connect the second lead to a good ground or to the antenna mounting bracket. 2. To retract antenna attach the battery positive source to the red wire terminal for the down direction. Connect the second lead to a good ground or to the antenna mounting bracket. 3. If the motor will not operate, replace the antenna assembly 4. If the motor runs freely and the antenna does not extend or retract, the mast or drive assembly is at fault. Remove the mast and verify that all the drive teeth are intact. If not replace mast. 5. If the mast jumps or travel rate is slow during operation or the motor labors. a. Check for bent mast. If bent replace mast. b. Check for dirty mast and clean it as necessary If corroded, replace mast. c. If cleaning the antenna sections does not solve the problem, the antenna mast should be replaced. 6. If mast fails to extend or retract completely, or motor continued to operate after full extension or retraction of mast. Check for broken teeth on the mast drive rod or bent mast. 7. If the mast checks good, the antenna assembly should be replaced. 8. Upon establishing that the fault is in the antenna assembly, it may be traced to one or more of the following conditions: a. Broken lead-in wire or shielding. b. Grounded lead-in wire or mast. c. Moisture in support tube or lead-in assembly d. Poor connection at antenna lead-in assembly or shielding ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Manual Antenna and Mast Antenna: Service and Repair Manual Antenna and Mast REMOVAL 1. Inside trunk, pull the right side trunk liner aside. 2. Unplug antenna lead from base of antenna body 3. Remove antenna mast by unscrewing mast from antenna body Antenna Mounting Removal 4. Remove screw from mounting bracket. 5. Pull antenna body down through the rubber grommet. INSTALLATION - For installation, reverse the above procedures. Check that the grommet locating tab is in-line with the slot in the body before installing antenna. Ensure the ball of the antenna body is inside grommet. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Manual Antenna and Mast > Page 6444 Antenna: Service and Repair Power Antenna REMOVAL 1. Disconnect battery negative cable. 2. Inside trunk, pull trunk liner aside. Power Antenna Assembly 3. Unplug antenna lead from pigtail connector, disconnect wire connector, remove drain tube from grommet. 4. Remove screws attaching ground strap and antenna brace. 5. Pull antenna body down through the rubber grommet. INSTALLATION - For installation reverse the above procedures. Check that the grommet locating tab is in-line with the slot in the body before installing antenna. Ensure the ball of antenna body is inside grommet. Tighten antenna bracket ground strap screws to 4 N.m (40 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Manual Antenna and Mast > Page 6445 Antenna: Service and Repair Power Antenna Mast REMOVAL 1. Remove cap nut. 2. Turn ignition key to ACCESSORY position and turn on radio. 3. While the mast is moving up pull upward to remove mast, contact spring and drive rod from the mast tube. INSTALLATION Power Antenna Mast Replacement 1. Insert new drive rod into mast tube with drive teeth toward antenna motor. 2. Turn off radio and guide mast into tube. The mast may not be fully lowered when first installed. 3. Replace the cap nut and tighten to 1.5 N.m (15 in.lbs.) torque. 4. Turn radio on and off to extend and retract antenna. Mast should be fully lowered after recycling. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch, Antitheft > Component Information > Description and Operation Arm/Disarm Switch: Description and Operation CIRCUIT OPERATION There are two switches used to ARM and DISARM the system. They are located in the left front and right front doors. These switches use resistors internal to the switch to send a signal to the Body Control Module (BCM) on the operators request. Power for the switches is supplied on circuit M1. This circuit is the Ignition-Off-Draw (IOD) circuit and is protected by a 10 amp fuse located in cavity 5 of the junction block. When the operator has selected the ARM or DISARM function voltage is supplied on circuit M1 through the CLOSED contacts in the switch, through the appropriate resistor, to the BCM. Circuit C73 is used as an input to the BCM for the left door switch, and circuit G72 is used for the right door switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION The Vehicle Theft Security System (VTSS) uses the door ajar switches to provide an input to the Body Control Module (BCM). These switches are normally OPEN with the doors CLOSED. When a door is opened the switch CLOSES completing a path to ground. Circuit G74 is used to monitor the right front, right rear, and the left rear door. The G75 circuit is used for the left front door. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 6453 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Remove door trim and water shield. VTSS Door Lock Switch Location 2. Remove illuminated entry switch wiring clip and disconnect connector. 3. Remove disarming switch from door handle. INSTALLATION - For installation reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Technical Service Bulletins > Customer Interest for Antenna - Keyless Entry: > 08-08-97 > Feb > 97 > Remote Keyless Entry - Inadequate/Intermittent Operation Antenna - Keyless Entry: Customer Interest Remote Keyless Entry - Inadequate/Intermittent Operation NO: 08-08-97 GROUP: Electrical DATE: Feb. 21, 1997 SUBJECT: RKE Inadequate/Intermittent Operation MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Less than expected range/reception (10 to 15 ft.) Or intermittent operation of the Remote Keyless Entry (RKE) system. DISCUSSION: The RKE system is made up of three components; transmitter, receiver, and antenna. The RKE antenna is the most likely cause of problems related to less than expected range/reception, intermittent operation, or apparent changes in operation with changes in weather. PARTS REQUIRED: 1 04897212AA Antenna, RKE AR 04318028 Tape, Vinyl Foam REPAIR PROCEDURE: This bulletin involves installing a revised RKE antenna. 1. Remove right and left instrument panel end covers. 2. Remove left A-pillar trim. 3. Remove instrument panel top cover. 4. Remove 2 bottom screws from left knee bolster panel. 5. Remove left under panel air distribution duct. 6. Remove either I/P mounting bolt from A-pillar. 7. Disconnect RKE antenna white 6-way connector (connector faces toward front of vehicle) from Body Control Module (BCM). Tape back or tie strap connector to harness. 8. Route new antenna harness, p/n 04897212AA, through gap between junction block and A-pillar. 9. Connect new antenna to BCM. 10. Route new antenna to top of I/P, wrap antenna with Mopar Vinyl Foam Tape, p/n 04318028, to prevent BSR's. Keep heat shrink wrapped portion of antenna as straight as possible along top of instrument panel when installed. 11. Secure new antenna ground eyelet under previously loosened I/P mounting bolt on A-pillar. 12. Install I/P trim panels. 13. Verify RKE operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-92-PX-90 0.4 Hrs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Technical Service Bulletins > Customer Interest for Antenna - Keyless Entry: > 08-08-97 > Feb > 97 > Remote Keyless Entry - Inadequate/Intermittent Operation > Page 6463 FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna - Keyless Entry: > 08-08-97 > Feb > 97 > Remote Keyless Entry - Inadequate/Intermittent Operation Antenna - Keyless Entry: All Technical Service Bulletins Remote Keyless Entry Inadequate/Intermittent Operation NO: 08-08-97 GROUP: Electrical DATE: Feb. 21, 1997 SUBJECT: RKE Inadequate/Intermittent Operation MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Less than expected range/reception (10 to 15 ft.) Or intermittent operation of the Remote Keyless Entry (RKE) system. DISCUSSION: The RKE system is made up of three components; transmitter, receiver, and antenna. The RKE antenna is the most likely cause of problems related to less than expected range/reception, intermittent operation, or apparent changes in operation with changes in weather. PARTS REQUIRED: 1 04897212AA Antenna, RKE AR 04318028 Tape, Vinyl Foam REPAIR PROCEDURE: This bulletin involves installing a revised RKE antenna. 1. Remove right and left instrument panel end covers. 2. Remove left A-pillar trim. 3. Remove instrument panel top cover. 4. Remove 2 bottom screws from left knee bolster panel. 5. Remove left under panel air distribution duct. 6. Remove either I/P mounting bolt from A-pillar. 7. Disconnect RKE antenna white 6-way connector (connector faces toward front of vehicle) from Body Control Module (BCM). Tape back or tie strap connector to harness. 8. Route new antenna harness, p/n 04897212AA, through gap between junction block and A-pillar. 9. Connect new antenna to BCM. 10. Route new antenna to top of I/P, wrap antenna with Mopar Vinyl Foam Tape, p/n 04318028, to prevent BSR's. Keep heat shrink wrapped portion of antenna as straight as possible along top of instrument panel when installed. 11. Secure new antenna ground eyelet under previously loosened I/P mounting bolt on A-pillar. 12. Install I/P trim panels. 13. Verify RKE operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-92-PX-90 0.4 Hrs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna - Keyless Entry: > 08-08-97 > Feb > 97 > Remote Keyless Entry - Inadequate/Intermittent Operation > Page 6469 FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > RKE Programming Keyless Entry Transmitter: Service and Repair RKE Programming Two (2) Button Transmitters TWO (2) BUTTON TRANSMITTERS To program an RKE transmitter, use the DRB and select "Body Computer", then "Miscellaneous", then "Program RKE". Push any button on the transmitter. The locks will lock or unlock to indicate that the BCM has received a useable code and will store it. If another transmitter is to be programmed, re-enter and repeat the steps. The BCM is capable of storing up to four transmitter codes. If an attempt to program a fifth transmitter is received, the DRB will inform that "All Locations Are In Use" and ask if you want to cancel them. If you answer yes, it will inform you that it is in programming mode. Press any button on a transmitter that you want to keep in memory. If you exit after answering yes, it will retain only the first transmitter code and cancel all others. Four (4) Button Transmitters FOUR (4) BUTTON TRANSMITTERS Using the DRB select "Body Computer", then "Miscellaneous" then "Program RKE". Press Lock and Decklid Release buttons simultaneously and hold for 5 seconds. All doors will unlock and will activate illuminated entry (if equipped) to indicate that the code has been programmed into the BCM's memory. Follow the same procedure for programming additional transmitters. A maximum of 4 transmitters can be programmed into the BCM at one time. If an attempt to program a fifth transmitter is received, the DRB will inform that "All Locations Are In Use" and ask if you want to cancel them. If you answer yes, it will inform you that you are in programming mode at which time you will program transmitters you want to keep in memory. If you exit after answering "Yes", it will retain only the first transmitter code and cancel all others. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > RKE Programming > Page 6474 Keyless Entry Transmitter: Service and Repair Enable/Disable Horn Chirp The DRB scan tool must be used to enable/disable the Horn Chirp. Refer to the DRB scan tool for the procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > RKE Programming > Page 6475 Keyless Entry Transmitter: Service and Repair Synchronization of Rolling Code Service The transmitter code will go out of synchronization if any button of a 4 button transmitter is pressed more than 250 times outside the range of the receiver which is inside the BCM. In other words the transmitter will not work. To synchronize the code of the particular transmitter with the receiver, press and hold both lock and decklid release buttons simultaneously for 5 seconds. Release the buttons and wait until the doors unlock indicating that the code has been synchronized. This may require waiting for as long as 6 minutes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Left Door Key Cylinder Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Left Door Key Cylinder Switch Connector > Page 6481 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation CIRCUIT OPERATION On vehicles equipped with the optional Vehicle Theft Security System (VTSS) a set lamp is located in the cluster. This lamp is powered by the F33 circuit and protected by a 20 amp fuse located in cavity 7 of the junction block. The Body Control Module (BCM) controls the ground path for the lamp on the G69 circuit. When the system is ARMING and SET the BCM grounds the G69 circuit and the lamp illuminates. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation > Page 6485 Security Lamp/Indicator: Testing and Inspection - Check the door ajar switches for a good ground Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION The trunk key cylinder switch is located on the trunk latch and is used as an input to the Body Control Module (BCM) when the key cylinder is being tampered with. This switch is normally CLOSED. Power for the switch is supplied on circuit G71 from the BCM. Ground for the switch is supplied on the Z1 circuit. When the key cylinder is being tampered with the switch OPENS and the path to ground is lost. The BCM then operates the alarm. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 6489 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The VTSS trunk lock switch is part of the trunk latch. For replacement, the trunk latch will need to be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6494 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6495 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6496 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6501 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6502 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6503 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation CIRCUIT OPERATION Garage Door Opener The garage door opener is powered by the 10 amp fuse located in the junction block on the M1 circuit. This fuse is the Ignition-Off Draw (IOD) fuse and is located in cavity 5. This circuit is HOT at all times. Ground for the opener is supplied on circuit Z1. This circuit terminates at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation Amplifier: Description and Operation SYSTEM OPERATION Remote Amplifier The amplifier is located under the right front seat. When the radio system is ON, and all or some speakers are not operating or have a noise distortion refer to the diagnostic tests. CIRCUIT OPERATION The power amplifier is used in the premium system only It is placed between the radio and the speakers. The feed for the amplifier is provided on the F30 circuit. The F30 circuit is protected by a 20 amp fuse located in cavity 8 of the junction block. Circuit F30 is spliced and provides power to the horns and the cigar lighter. Ground is provided on the Z1 circuit and terminates at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6511 Amplifier: Testing and Inspection Amplified Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6512 Amplified Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6513 Amplified Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6514 Amplified Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6515 Amplified Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6516 Amplified Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6517 Amplifier: Service and Repair REMOVAL 1. Remove the right front seat. Amplifier Locations 2. Remove the two screws and one nut attaching the amplifier. 3. Disconnect the electrical connectors and remove. INSTALLATION - For installation, reverse the above procedures. Tighten fasteners to 4 N.m (40 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Technical Service Bulletins > CD Changer - Rattle Noise CD Changer: Technical Service Bulletins CD Changer - Rattle Noise NO: 08-44-96 GROUP: Electrical DATE: Dec. 6, 1996 SUBJECT: CD Changer Rattle MODELS: 1997 (JA) Breeze/Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT SEPT. 4, 1996 THRU SEPT. 24, 1996 (MDH 09-04-XX THRU 09-24-XX). THE CD CHANGER DATE CODE CAN BE USED TO IDENTIFY SUSPECT UNITS. THE SUSPECT DATE CODE IS 1926( ONE HUNDRED AND NINETY SECOND DAY OF 1996). THE DATE CODE IS LOCATED ON THE CD CHANGER PART NUMBER LABEL (LABEL ON BACK OF CD CHANGER NEAR WIRE CONNECTOR) AND NO BLUE DOT ON THE ASSEMBLY PART NUMBER (ASSEMBLY PART NUMBER LABEL IS LOCATED ON THE TOP OF THE CD CHANGER ASSEMBLY BRACKET). SYMPTOM/CONDITION: Rattle noise coming from CD changer. Noise can be induced when CD changer door is open, CD cassette is removed, and/or vehicle is driven over small bumps/potholes at varied speeds. DIAGNOSIS: Road test vehicle, verify rattle noise is coming from CD changer, perform Repair Procedure. REPAIR PROCEDURE: This bulletin involves removing the CD changer and sending it to the Authorized Repair center. 1. Remove instrument cluster bezel to gain access to CD changer. 2. Remove CD changer and send to your local Alpine Authorized Repair Center (listed on DIAL Function 51 Warranty Bulletin Board). NOTE: NOTING THIS TECHNICAL SERVICE BULLETIN ON THE REPAIR CLAIM WILL SPEED SERVICING OF THE AFFECTED UNITS. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 Radio/Stereo: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 Radio/Stereo: Connector Views Radio Connectors Radio Connectors Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Radio/Stereo: Electrical Diagrams Standard Radio Audio System NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Premium Radio Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 Audio System (Part 1 Of 3) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 Audio System (Part 2 Of 3) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 Audio System (Part 3 Of 3) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6548 Radio/Stereo: Description and Operation INTRODUCTION For operation of the factory installed standard and optional radios with cassette or compact disc player, refer to the Sound Systems Operating Instructions in the Owners Manual supplied with the vehicle. The vehicles are shipped with fuse 5 removed from the Junction Block. The fuse replaces the ignition-off draw (IOD) connector. Fuse 5 is a ten amp fuse. When removed it prevents the battery from discharging during storage. SYSTEM OPERATION Interference Elimination Some components used on the vehicles are equipped with a capacitor to suppress radio frequency interference/static. Capacitors are mounted in various locations internal to the generator, instrument cluster and windshield wiper motor. A ground strap is mounted from the engine to shock tower. On four cylinder engines, there is a ground strap from the rear of the muffler to the muffler mounting bracket. These ground circuits should be securely tightened to assure good metal to metal contact. Ground straps conduct very small high frequency electrical signals to ground and require clean large surface area contact. The radio grounds to the cross car beam through pinch brackets that grounds automatically as the radio is installed into the instrument panel. Radio resistance type spark plug cables in the high tension circuit of the ignition system complete the interference suppression. Faulty or deteriorated spark plug wires should be replaced. Power Antenna The power operated radio antenna is a telescoping type antenna, extended and retracted by a reversible electric motor. The Automatic Power Antenna is controlled by a combination of an internal relay and limit switches which, are built into the antenna motor housing. This antenna is actuated when the radio is switched ON and the ignition switch in ON or ACCESSORY position. When the ignition switch or the radio is turned OFF the antenna mast should retract fully. Many antenna problems may be avoided by frequent cleaning of the antenna mast telescoping sections. Clean the antenna mast sections with a clean soft cloth. Before an antenna is removed, the antenna performance should be tested to decide if it is a reception problem or an operational problem. Whenever a operational malfunction occurs, first verify that the radio antenna wire harness is properly connected. Check all connectors before starting normal diagnosis and repair procedures. Remote Amplifier The amplifier is located under the right front seat. When the radio system is ON, and all or some speakers are not operating or have a noise distortion refer to the diagnostic tests. CIRCUIT OPERATION Radio Operation There are two audio systems offered on this vehicle. The base system uses four speakers and a standard antenna. The optional system has six speakers, power amplifier, and a power antenna. Both systems are powered by a 10 amp fuse located in cavity 14 of the junction block on circuit X12. This fuse is HOT when the ignition switch is in the ACCESSORY or RUN position. The A31 circuit, which receives it's power from the ignition switch, on circuit A1, is protected by a 20 amp fuse located in cavity 8 of the Power Distribution Center (PDC). Both the standard and optional radios use an external case ground. This case ground attaches to the rear of the radio and the instrument panel. Radio Memory Both the base and premium systems use the M1 circuit to maintain radio memory. This circuit is connected to the battery through the Power Distribution Center (PDC), and protected by a 10 amp Ignition Off Draw (IOD) fuse. The M1 circuit is used to supply power to the Body Control Module (BCM), Power Mirrors, and the Power Door Locks. This fuse is also used in several other circuits. The IOD fuse is removed during vehicle shipping to prevent excessive battery draw. Radio Illumination when the parking lamps or the headlamps are ON, circuits E2 and L7 are used to power the radio illumination lamps. Circuit E2 is controlled by the Body Control Module (BCM). Circuit L7 is controlled by the park lamp switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6549 Radio/Stereo: Service and Repair REMOVAL Center Bezel Removal 1. Remove center bezel by pulling straight back. Radio Assembly 2. Remove two radio mounting screws. 3. Turn OFF radio and ignition switch. DO NOT disconnect the radio with ignition switch ON. 4. Pull radio from panel and disconnect wire connectors and antenna lead from radio. 5. Remove radio. INSTALLATION - For installation, reverse the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation Speaker: Description and Operation CIRCUIT OPERATION Base System Circuit X53 is the feed to the left front door speaker. Circuit X55 is the return from the speaker to the radio. Circuit X54 is the feed to the right front door speaker. Circuit X56 is the return from the speaker to the radio. Circuit X51 is the feed to the left rear speaker. Circuit X57 is the return from the speaker to the radio. Circuit X52 is the feed to the right rear speaker. Circuit X58 is the return from the speaker to the radio. Premium System Circuit X53 is the feed for the left front speaker to the power amplifier. Circuit X55 is the return from the amplifier to the radio. Circuit X54 is the feed for the right front speaker to the power amplifier. Circuit X55 is the return from the amplifier to the radio. Circuit X51 is the feed for the left rear speaker to the power amplifier. Circuit X57 is the return from the amplifier to the radio. Circuit X53 is the feed for the left front speaker to the power amplifier. Circuit X55 is the return from the amplifier to the radio. Circuit X52 is the feed for the right rear speaker to the power amplifier. Circuit X58 is the return from the amplifier to the radio. Circuits X84 and X86 supply power and ground for the right front instrument panel speaker. Circuits X83 and X81 supply power and ground for the left front instrument panel speaker. Circuits X87 and X85 supply power and ground for the left front door speaker. Circuits X82 and X80 supply power and ground for the right front door speaker. Circuits X91, X93, X95, and X97 supply power and ground for the left rear speaker. Circuits X92, X94, X96, and X98 supply power and ground for the left rear speaker. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Base 4 Speaker System Speaker: Testing and Inspection Base 4 Speaker System Base 4 Speaker System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Base 4 Speaker System > Page 6555 Base 4 Speaker System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Base 4 Speaker System > Page 6556 Base 4 Speaker System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Base 4 Speaker System > Page 6557 Base 4 Speaker System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Base 4 Speaker System > Page 6558 Speaker: Testing and Inspection Helpful Information - Check for a blown 20 amp fuse in cavity 8 of the junction block - Check the 20 amp fuse located in cavity 8 of the PDC - Check the case ground attached to the rear of the radio - Check the 10 amp IOD fuse located in cavity 5 of the junction block Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Rear Speaker Speaker: Service and Repair Rear Speaker REMOVAL CAUTION: Do not operate the radio with speaker leads detached. Damage to the output devices may result. The wire connectors can be accessed through the trunk. REMOVAL 1. Remove parcel shelf panel. Rear Speakers 2. Remove four retaining screws. 3. Disconnect wire connector and remove speaker. INSTALLATION For installation, reverse the above procedures. Be sure that the wire connectors are facing outward in vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Rear Speaker > Page 6561 Speaker: Service and Repair Door Mounted Speaker REMOVAL CAUTION: Do not operate the radio with speaker leads detached. Damage to the output devices may result. Door Mounted Speaker 1. Remove window crank handle if equipped. Carefully, pry speaker grille away from door trim panel. 2. Remove three speaker retaining screws. 3. Pull speaker away from door and disconnect wiring. INSTALLATION - For installation, reverse the above procedures. Ensure speaker is in the proper position Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Rear Speaker > Page 6562 Speaker: Service and Repair Instrument Panel Speaker REMOVAL CAUTION: Do not operate the radio with speaker leads detached. Damage to the output devices may result. 1. Remove instrument panel top cover. a. Remove screw from right side of the top cover. Instrument Panel Top Cover b. Carefully, pry up each end of top cover to disengage clips. c. Lift rear edge of top cover using a trim stick along rear edge. d. While lifting rear edge slide top cover rearward to disengage front clips and remove the top cover. Instrument Panel Speakers 2. To remove right or left speaker remove two retaining screws. Lift up speaker and disconnect wire connector. INSTALLATION - For installation, reverse the above procedures. Ensure speaker is in the proper position Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Description and Operation Arm/Disarm Switch: Description and Operation CIRCUIT OPERATION There are two switches used to ARM and DISARM the system. They are located in the left front and right front doors. These switches use resistors internal to the switch to send a signal to the Body Control Module (BCM) on the operators request. Power for the switches is supplied on circuit M1. This circuit is the Ignition-Off-Draw (IOD) circuit and is protected by a 10 amp fuse located in cavity 5 of the junction block. When the operator has selected the ARM or DISARM function voltage is supplied on circuit M1 through the CLOSED contacts in the switch, through the appropriate resistor, to the BCM. Circuit C73 is used as an input to the BCM for the left door switch, and circuit G72 is used for the right door switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION The Vehicle Theft Security System (VTSS) uses the door ajar switches to provide an input to the Body Control Module (BCM). These switches are normally OPEN with the doors CLOSED. When a door is opened the switch CLOSES completing a path to ground. Circuit G74 is used to monitor the right front, right rear, and the left rear door. The G75 circuit is used for the left front door. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 6570 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Remove door trim and water shield. VTSS Door Lock Switch Location 2. Remove illuminated entry switch wiring clip and disconnect connector. 3. Remove disarming switch from door handle. INSTALLATION - For installation reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Left Door Key Cylinder Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Left Door Key Cylinder Switch Connector > Page 6576 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation Trunk/Liftgate Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION The trunk key cylinder switch is located on the trunk latch and is used as an input to the Body Control Module (BCM) when the key cylinder is being tampered with. This switch is normally CLOSED. Power for the switch is supplied on circuit G71 from the BCM. Ground for the switch is supplied on the Z1 circuit. When the key cylinder is being tampered with the switch OPENS and the path to ground is lost. The BCM then operates the alarm. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 6580 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair The VTSS trunk lock switch is part of the trunk latch. For replacement, the trunk latch will need to be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions Trip Computer: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 Trip Computer: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 Trip Computer: Electrical Diagrams Traveler Traveler NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 6605 Trip Computer: Description and Operation SYSTEM OPERATION Compass/Temperature Mini-Trip Computer CTMC Module Compass/Temperature Mini-trip Computer The Compass/Temperature Mini-Trip Computer (CMTC) system is located on the right hand side of the instrument panel cluster. The CMTC is an electronic control module with a vacuum fluorescent display and two function buttons. The CMTC is capable of displaying compass, temperature, and trip computer information. Actuation of the STEP button will cause the CMTC to change mode of operation and actuation of the US/M button will toggle between English and Metric unit of measurement. A reset of the trip computer information is accomplished by actuating the Step and US/M buttons simultaneously. The CMTC is active only when the ignition switch is in the ON position. When the ignition switch is turned ON, the CMTC will turn on all of the segments in the display for one second then return to the last function screen that was displayed prior to the ignition being turned OFF. The functions that are available via activation of the STEP switch are as follow: Compass and Ambient Temperature - Average Trip Fuel Economy (AVG ECO) - Estimated Range (RANGE) - Present Fuel Economy (ECO) - Trip Odometer (ODO) - Elapsed Ignition On Time (ET) - Blank Screen (OFF) Compass The CMTC is an auto-calibrating compass and requires no activation of any switches to trigger a forced calibration. The compass is initially setup to be calibrated for earth fields of approximately 180 milligauss. However, due to the variation in the magnetic earth field across the country and the variation of the magnetic structure from vehicle to vehicle the compass may need to be calibrated. Refer to Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection/Procedures/Compass Calibration Service Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 6606 Ambient Temperature The temperature is displayed in whole degrees Celsius or Fahrenheit. Temperatures greater than or equal to zero are displayed unsigned and temperatures below zero are displayed signed (-). If the temperature is more than 55 °C (131 °F) or the temperature sending line is shorted to ground, the compass and ambient temperature screen will display SC. If the temperature is less than -40 °C (-40 °F) or the temperature sending line is an open circuit, the compass and ambient temperature screen will OC. If the message CCD bus to display the ambient temperature. Mini Trip Computer Messages The Mini Trip Computer data is obtained from information put on the CCD bus from thee Powertrain Control Module and the Body Control Module. The CMTC will not display information for any of the screens for which it did not receive the proper data over the CCD bus for that particular screen. In which case the message CCD will be displayed. If the CCD message is displayed on all the screens of the CCD bus with a scan tool (DRB). If some of the screens appear to be functioning properly but some of the screens display CCD then check either the Powertrain Control Module or the Body Control Module for proper CCD bus communications. If the CCD message still persist refer to the Mini Trip Computer Self Diagnostic Test. CIRCUIT OPERATION Traveler Power for the traveler is supplied from two sources. There is a constant battery feed on circuit M1. This is the Ignition Off Draw (IOD) circuit and is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the traveler on circuit F18. This circuit is HOT in the START and RUN position and protected by a 10 amp fuse located in cavity 9 of the Power Distribution Center (PDC). Power for the fuse is supplied on circuit A21 from the ignition switch. Ground for the traveler is supplied on circuit Z1. This circuit terminates at the instrument panel left side cowl. The traveler is also interfaced with the CCD Bus. This interface allows the traveler to receive the necessary information for display to the operator. The circuits involved are D1 for CCD (+), and D2 for CCD (-). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and Inspection > Helpful Information Trip Computer: Testing and Inspection Helpful Information - Check the 10 amp IOD fuse in cavity 5 of the junction block - Check the 10 amp fuse located in cavity 9 of the PDC - Check the ground at the instrument panel left side cowl Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and Inspection > Helpful Information > Page 6609 Trip Computer: Testing and Inspection Testing The CMTC is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a scan tool (DRB) and the proper Body Diagnostic Procedures manual or by the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP button. 2. Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display Upon completion of the internal check, the CMTC will display: - PASS - FAIL - CCD If any segment of the CMTC fails to light replace the module. If FAIL is displayed, replace the module. If CCD is displayed, check the CCD and Body Control Module (BCM) for proper operation, refer to the appropriate diagnostic test procedures. If the CCD and the BCM are OK, replace the CMTC module. For additional diagnostic information on the CMTC and for identifying CMTC problems, refer to the proper Body Diagnostic Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and Inspection > Helpful Information > Page 6610 Trip Computer: Testing and Inspection Diagnostic Charts This system is related to the Body Control System. For complete testing -- including Diagnostic Charts -- SEE Body Control Module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations ETACS-ECU ETACS-ECU Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Body Control Module: Connector Views Body 20 Way Connector (At BCM) Engine 14 Way Connector (At BCM) Instrument Panel 10-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 Instrument Panel 22-Way Connector (At BCM) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Body Control Module: Electrical Diagrams Body Control Module Wiring Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information Technician Safety Information WARNING: Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. 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. SERVICING SUB-ASSEMBLIES 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. Only those components with approved Service and Repair procedures in this database should be serviced. DRBIII Scantool Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. - Follow the vehicle manufacturer's service specifications at all times. - Do not use the DRB if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. - Do not exceed the limits shown in the table above. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 6649 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". 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 because of corrosion. 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. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms Body Control Module: Application and ID Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The terms "gage" and "gauge" are used interchangeably Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Application and ID > Glossary of Terms/Acronyms > Page 6652 Body Control Module: Application and ID Body Codes Defined JA ............................................................................................................................................................ Chrysler Cirrus, Plymouth Breeze, Dodge Stratus JX ......................................................................... ................................................................................................................... Chrysler Sebring Convertible Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Active Codes: A malfunction that is present now. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6655 ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6656 Body Control Module: Description and Operation Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6657 Body Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6658 Body Control Module: Description and Operation Climate Control Systems A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6659 Body Control Module: Description and Operation Airbag System Fig. 1 Airbag Restraint System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front-end collision. The system is most effective when used in conjunction with the seat belt system. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM is an electronically-triggered system that used only its own internal electronic sensor to trigger the airbags. The JA and JX Bodies used only the AECM system. Whenever the ignition key is turned to the "run" or "start" position, the Airbag Control Module (ACM) performs a lamp check by turning the AIRBAG 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 airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag 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 airbag system to the technician through the DRB via the CCD bus. 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 airbags. The total time between determining to deploy and deflation of the airbag is 1/10th of a second. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all - warning lamp stays on COMPONENTS The major components of the SRS are; - The Airbag Module - The Clockspring - The Impact Sensors - The Airbag System Diagnostic Module (ASDM or PASDM). If any of these parts should fail, they must be replaced, as they cannot be repaired. NOTE: Use the test procedures in Testing & Inspection to find the cause of any customer complaint regarding the "Air Bag" warning lamp. GLOSSARY OF TERMS USED Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6660 Active Codes: A malfunction that is present now. ACM: Airbag Control Module (also called the Air Bag System Diagnostic Module (ASDM)). ASDM: Air Bag System Diagnostic Module (also called the Airbag Control Module (ACM)). Air Bag Module: Also called "Squib" initiator - located inside the air bag module assembly. Impact Sensor: G force sensitive, threshold switches which close when an impact of sufficient force in the correct direction occurs. An impact switch closure accompanied by closure of the safing sensor, alerts the control module that it is now time to deploy the airbag(s). Initiator: Also called "Squib" - located inside the air bag module assembly. PASDM: Passenger Air Bag System Diagnostic Module Safing Sensor: A switch inside the ASDM which must be closed at the same time at least one of the impact sensors is closed, to initiate deployment of the airbag(s). Squib: Also called "Air Bag Module" initiator - located inside the air bag module assembly. SRS: Supplemental Restraint System Stored Codes: A malfunction that had been present during a previous key cycle, may or may not be active. Body Control Module BODY CONTROL MODULE The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus, or CCD bus). This network consists of the Powertrain Control Module (PCM), the Transmission Control Module (TCM), the Electro/Mechanical Instrument Cluster (MIC), the compass/mini-trip module and the Airbag Control Module (ACM). The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switched functions. The body control module provides the following features: - A/C switch status/evaporator temperature status - Automatic door locks - Chimes - Courtesy lamps - BCM diagnostic support - Door lock inhibit - Headlamp time delay - Ignition key lamp - Illuminated entry with "fade to off" (JA models) - Instrument panel dimming - Manual A/C (mode door control) - Mechanical instrument cluster support - Power door locks (with/without remote keyless entry) - Vehicle Theft Security System (VTSS) - Windshield wiper/washer Circuit Operation CIRCUIT OPERATION The Body Control Module (BCM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the BCM is supplied from four sources. One is the M1 circuit. This circuit is HOT at all times, and is the Ignition-Off Draw (IOD) circuit. This circuit is protected by a 10 amp fuse located in cavity 5 of the junction block. Power is also supplied to the BCM on circuit A21. This circuit is HOT when the ignition switch is in the START/RUN position only, and connects from the ignition switch to the BCM. Power for the A21 circuit is supplied by circuit A1. Circuit A1 is connected between the PDC and the ignition switch and is protected by a 20 amp fuse located in cavity 8 of the PDC. Circuit F11, which is HOT when the ignition switch is in the OFF/RUN/START position, supplies a constant feed to the BCM. This circuit is Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6661 protected by a 10 amp fuse located in cavity 11 of the junction block. Power for the fuse is supplied on circuit A81 from the ignition switch. Circuit A81 receives its power from circuit A1 which originates in the PDC and is protected by a 20 amp fuse located in cavity 8. Circuit F135 also supplies power to the BCM and is protected by a 15 amp fuse located in cavity 9 of the junction block. This circuit is used for the feed to the power door lock motors. Ground for the BCM is provided by circuits Z1 and Z2. These circuits terminate at the instrument panel left side cowl. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+) and D2 is for Bus (-). A/C Switch Status/Evaporator Temperature Status A/C SWITCH STATUS/EVAPORATOR TEMPERATURE STATUS When the ignition is in the "run" position, the Body Control Module (BCM) monitors the evaporator temperature and the status of the A/C switch. Based on this information, the BCM sends a CCD message to the Powertrain Control Module (PCM) indicating the A/C switch status and the evaporator temperature status. Manual A/C (HVAC) MANUAL A/C (HVAC) The Body Control Module (BCM) controls the mode door position by receiving different voltage levels from the HVAC control over the HVAC mode sense circuit. Included in this signal is the input for the rear window defogger. In this system, the body control module has no control of the blower motor or the passenger compartment temperature. Compass Mini-Trip Computer (CMTC) COMPASS/MINI-TRIP COMPUTER The Compass/Mini-Trip Computer (CMTC) system is located on the right hand side of the instrument cluster. The CMTC is an electronic control module with a Vacuum Fluorescent Display (VFD) and two function switches. The CMTC is capable of displaying compass, temperature and trip computer information. Actuation of the STEP switch will cause the CMTC to change mode of operation while actuation of the US/M switch will toggle between English and Metric units. A reset of the trip computer is accomplished by pressing the STEP and US/M switches simultaneously. The CMTC is active only when the ignition is on. Upon ignition the CMTC will turn on all of the segments in the display for 1 second then reverts to the last function screen that was displayed prior to the last ignition cycle. The functions that are available via actuation of the STEP switch are as follows: - Compass and Ambient Temperature - Average Trip Fuel Economy (AVE ECO) - Estimated Range (RANGE) - Present Fuel Economy (ECO) - Trip Odometer (ODO) - Elapsed Ignition On Time (ET) - Blank Screen (off) Glossary of Terms/Acronyms GLOSSARY OF TERMS ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CCD Chrysler Collision Detection (vehicle Communications Bus) DAB Driver Airbag DLC Data Link Connector EBL Electric Back Lite (rear Window Defogger) HVAC Heater, Ventilation, Air Conditioning MET Metric MIC Mechanical Instrument Cluster MFCM Multi-function Control Module ODO Odometer PAB Passenger Airbag PCM Powertrain Control Module PDC Power Distribution Center RKE Remote Keyless Entry SBCM Seat Belt Control Module TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6662 NOTE: The terms "gage" and "gauge" are used interchangeably Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular position of four gauges, the status of seven indicator lamps, the status and dimming of the PRNDL indicator (VF display), and the dimming of cruise and low fuel lamps to the Mechanical Instrument Cluster (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run," or "start" positions. The PRNDL indicator works when the ignition is in the "off," "run," or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all PRNDL segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the tachometer exceeds 450 rpm. Power Door Lock System POWER DOOR LOCK SYSTEM When the Body Control Module (BCM) receives an input for a lock/unlock request (door lock switch, Remote Keyless Entry (RKE), or door key cylinder switch (w/VTSS only), it will ground the appropriate relay for a specified amount of time. For this vehicle all door lock relays are located inside the body control module and are not serviced separately. The door lock switches provide a variable voltage (Multiplexed (MUX) circuit) to the BCM and the BCM will respond to that command. If the conditions for door lock inhibit exist (key in ignition and left front door open), the BCM will not respond to a lock command. Other power door lock features: Automatic Door Locks This feature can be enabled/disabled by using either the DRB, MDS machine or customer key cycle method. When enabled, all the doors will lock when the vehicle reaches a speed greater than 15 MPH, all doors are closed and an increase of TPS signal is received by the PCM. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the vehicle speed accelerates above 15 MPH. Remote Keyless Entry (RKE) The body control module receives and decodes messages from the remote keyless entry transmitter. The remote keyless entry module is built into the BCM (premium) and is not serviced separately. When the lock button is pressed all doors will lock, horn will chirp, courtesy lamps will turn off and VTSS (if equipped) will arm. When the unlock button is pressed once, the left front door will unlock, courtesy lamps will light (if equipped w/illuminated entry) and VTSS (if equipped) will disarm. If the unlock button is pressed a second time (within 5 seconds of the first), all the other doors will unlock. Panic mode (if equipped with VTSS), is accomplished by pressing both lock and unlock buttons at the same time. 1997 JX transmitters have a separate panic button. This flashes the lights and sounds the horn but does not prevent the engine from running. The BCM will ignore all commands from the transmitter if the vehicle speed is over 15 MPH. This allows the engine to be running during warm up on cold days and then using the RKE to unlock the doors. The RKE software can store up to 4 transmitter codes. Rolling Code (97 JX only) The rolling code features changes part of the key fob (transmitter) message each time it is used. The key fob message and the receiver message increment together. Under certain conditions with a rolling code system (like pressing a button on the fob over 250 times outside of the receiver range) the receiver and transmitter can fall out of synchronization. By pressing specific buttons together, the system will re-synchronize. Radio-CCD RADIO - CCD NOTE: At the present time all 1997 CCD radios are not connected to the CCD bus. The audio systems used in the JX convertible will consist of one of the following radios: RAL Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6663 RAL - Base radio with AM/FM stereo, bass and treble sliders only. RBS RBS - AM/FM stereo with cassette tape and CD changer option. Bass and treble controls. This radio may or may not be addressable with DRB. If it is equipped with the Premium Amplifier option (located under the passenger seat), it will be on the CCD bus. The Amplifier will determine whether the CCD connector in the back of the radio is wired. RBR RBR - AM/FM stereo with CD player only. Three band E.Q. Not connected to the bus. Not addressable with DRB. RAZ RAZ - AM/FM stereo with cassette and CD player incorporated into one unit. This system will be equipped with the Premium Amplifier package and will be addressable with the DRB. The amplifier as above is located under the passenger seat. The audio systems available in the JX are made up of the four corporate radios listed above with some additional options with regard to the amplification system. The list breaks down how the separate systems are made up. There are only two of the four radios that will be addressable on the CCD bus with the DRB. The key to knowing which system is addressable is the presence of an amplifier under the passenger seat. This amplifier utilizes a different instrument panel wiring harness that incorporates the CCD connector for the radio. Some of the radios may have a CCD connector in the radio chassis that may not have a connector plugged into it. This is entirely normal if there is no amplifier under the passenger seat. The RBS radio will be available with or without the premium amplifier and therefore will not be addressable via the CCD bus in some packages. When equipped with a Premium Amplifier package, there will be six speakers in the can The amplifier will drive the instrument panel speakers and the door speakers, while the radio will drive the speakers located in the rear quarter panels directly. This means that a "shorted channel" DTC can now be caused by a problem with the wiring or the resistance of the rear quarter panel speakers. In the past, the amplifier (if equipped) drove all the speakers and consequently the circuits from the amplifier to the speakers and the speakers themselves could not be the cause of a shorted channel DTC. 3.8.1 Diagnostics DIAGNOSTICS The RBS radio has several diagnostic messages that may be displayed in the event of a problem with either the radio or the CD changer option. These messages will be displayed on the radio faceplate in the following abbreviated form. The messages are as follows: Display Definition E L-SP LEFT CHANNEL SHORT Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6664 E R-SP RIGHT CHANNEL SHORT E EJCT CANNOT EJECT TAPE E LOAD CANNOT LOAD TAPE E PLAY CANNOT PLAY TAPE The following messages are for the CD changer options; E HOT THE CD CHANGER INTERNAL TEMPERATURE IS TOO HIGH E E-O1 CD CHANGER DEADLOCK (CD JAMMED, CAN'T LOAD OR EJECT) E E-06 CD CHANGER ELEVATOR ERROR E E-07 MAGAZINE EJECT ERROR E EEEE COMMUNICATIONS ERROR (BETWEEN RADIO AND CHANGER) E PLAY CANNOT READ ALL DISCS The left channel short, right channel short and communication error between the radio and CD changer are addressed in the diagnostics. Generally, the rest of the messages will require removal and repair of either the radio or the CD changer. NOTE: When using the diagnostic manual for troubleshooting radio systems, all voltages are D.C. unless otherwise specified. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against vehicle theft. The Vehicle Theft Security System (VTSS) module is a logic-controlled device (part of the body control module), that monitors vehicle doors, trunk key cylinder, and ignition action for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, courtesy and VTSS lamps, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door. Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the cluster will flash fast for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the trunk key cylinder switch is not seen by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. The indicator lamp blinks at a slow rate when the system is armed. For 1997 JX vehicles, once the VTSS is armed the universal garage door opener (if equipped) and the decklid release switch in the center console will be disabled. The decklid release will still operate from the RKE or using the key. When something triggers the alarm, the system will signal for about 18 minutes. For the first three minutes the horn will sound, then the headlamps and courtesy lamps will continue to flash for another 15 minutes. Tamper Alert - If the horn sounds three times when either front door is unlocked, it means the alarm was activated. Check the vehicle for tampering. The VTSS indicator lamp will also flash twice quickly to indicate a tamper condition has occurred. Manual Override - The system will not arm if the doors are locked using the manual lock control. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by communication between the powertrain control module and the body control module. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has been activated. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6665 System Self-Tests - NOTE: System self-tests can be entered only with the DRB or MDS machine. Upon entering diagnostics, the headlamps, courtesy lamps and VTSS lamp will begin flashing to verify their operation. In addition, the horn will sound twice. Removing the key from the ignition switch will stop the lamps from flashing while keeping the system in diagnostics. While in diagnostics mode, a horn pulse should occur at each of the following events, which indicates proper operation. 1. Beginning with all doors closed, open, then close each door. The horn will sound when the door ajar switch closes, and then again when the switch opens. There must be a one-second delay between closing and opening the switch. 2. Rotate the key in each door lock cylinder to the unlock position. The horn will sound as the switch closes, and again when it opens. There must be a one-second delay between changing switch states, or the horn will not sound. 3. Cycle the key to the ignition RUN position. A single horn pulse will indicate proper operation of the ignition input. This also will take the module out of the diagnostics mode. For any of these tests, if the switch does not remain open or closed for at least one second, the horn will only sound once. The lack of a horn pulse during any operation indicates either: - a switch failure - the lack of that input to the vehicle theft security system module - a failure internal to the module - a faulty horn system Check for continuity at the switch. If this is good, check for an open or shorted wire between the switch and alarm module. Also, check if the Powertrain Control Module (PCM) has been replaced recently. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Vehicle Communication VEHICLE COMMUNICATION The body system consists of a combination of modules that communicate 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 the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver 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 code determines the message that has higher priority, which is then allowed to access the bus first. The two wires 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. 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: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection for diagnostic and repair procedures. Any of the following bus failure messages may be displayed: Short to Battery Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground Either or both of the bus wires are shorted to ground or a specific ground may be open. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 6666 Bus (+) & (-) Shorted Together The two bus wires are shorted together. No Termination The bus system has lost connection with all of its terminators. Bus Bias Level Too Low Either or both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High Either or both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias The bus system has lost connection with all modules that provide bias. Bus (+) Open The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open The bus (-) wire has lost connection with termination and/or bias. Not Receiving Bus Messages Correctly The DRB cannot communicate over the bus and does not know why. Wiper System WIPER SYSTEM The front wiper system provides the driver with normal wipe (low and high speeds), intermittent wipe, wiper after wash, and mist wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. Other wiper system features: Speed Sensitive Intermittent Wipe Mode There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled providing a range of from 1 second to 36 seconds. Mist Wipe When the wiper is in the off position and the driver presses the mist control for more than 125 msec, 1 wipe cycle in low speed mode will be provided. The wipe will continue in low speed as long as the switch is held in that position. Wiper After Wash Mode When the driver presses the wash button for over 3/8 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Body Control Module: Reading and Clearing Diagnostic Trouble Codes Displaying & Reading Trouble Codes CCD Data Link Connector Tip: Reading codes requires the use of a DRBII Diagnostic Readout Box or Equivalent Scan Tool. WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 10 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. NOTE: These diagnostic test procedures have been designed specifically for use with the Chrysler DRBII (Diagnostic Readout Box II). However it should be possible to perform the same tests using an equivalent Scan Tool. NOTE: It is not necessary to perform all of the tests in Diagnostic Charts to diagnose an individual code. Clearing Trouble Codes To clear codes, all codes must be "read," then proceed as follows: 1. After all codes have been read, press ATM. The display will change to the ERASE menu screen. 2. Press "1 ERASE CODES" to erase all codes. The display will return to the airbag menu screen. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6669 Body Control Module: Component Tests and General Diagnostics Diagnostic Notes - Read First 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. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active code(s). Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. 3.12.1 Active Codes ACTIVE CODES An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. 3.12.2 Stored Codes STORED CODES Airbag codes are automatically stored in the ACM's memory when the ignition is turned off with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6670 If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on," wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Manual A/C (HVAC) - Mode Door Operation MANUAL A/C (HVAC) MODE DOOR OPERATION The DRB trouble codes that indicate a stall failure or a feedback signal failure work together to show what is wrong with the HVAC system. The stall trouble codes mean that the Body Control Module (BCM) cannot force an actuator to the end of the mode door travel. Internal problems in the body control module will set other short-related trouble codes. Having only stall trouble codes indicates that there is a problem with an open or short circuit in the wiring, a bad actuator, a bad mode door or connecting linkage. It is important that the operation of the mode door be checked if an actuator is removed. This can be checked by rotating the door shaft to confirm that the door will stop at both ends of travel. The actuator itself has no stops. It must have the mode door to stop travel to pass the stall test. A feedback signal failure can occur on the mode door. The body control module monitors the feedback signal to check the position of the actuator. The body control module not only checks the level of the signal but also how much the voltage changes. A feedback failure can occur if there is a short or open circuit in the wiring, a bad actuator, a bad body control module, a bad mode door or connecting linkage. The easiest way to diagnose this is to use the DRB to actuate the mode door. Note that the feedback voltage of the actuator should smoothly change as the actuator is moved. A sudden change in the feedback voltage to a 5.0-volt or a 0.0-volt level indicates the actuator is bad. A fixed feedback voltage that is less than 5.0 volts or greater than 0.0 volts without a stall failure, or a short failure indicates that the actuator, the mode door, or a connecting mechanical linkage is jammed preventing movement. A feedback signal voltage that stays on 5.0 volts or 0.0 volts indicates a wiring or body control module problem. The feedback failure trouble code can also occur from a lack of actuator travel. This can be checked by confirming that the feedback signal smoothly changes when the actuator is moved with the DRB. If the signal is ok, the door travel is not correct. The actuator must be removed and the mode door mechanically checked for proper operation. Typical problems that prevent door movement include screws dropped in the A/C unit or warped doors. Replace any part that is found defective. Anytime the voltage to the BCM is interrupted for less than 2 minutes or voltage drops below approximately 10.0 volts (battery disconnected, etc.), it may be necessary to recalibrate the mode door. This can be done by using the DRB, MDS machine or removing the IOD (M1) fuse for 10 seconds, reinstall it and then start the engine. Diagnostic Strategies ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 6671 Body Control Module: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRBIII DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform VEHICLE COMMUNICATION TEST 1A. DRBIII Error Messages DRBIII ERROR MESSAGE Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 6672 Body Control Module: Service and Repair JUNCTION BLOCK REMOVAL Junction Block/BCM Location The Junction Block and Body Control Module (BCM) are attached to each other. After removal they can be separated. Junction Block and Body Control Module assemblies are located on the driver's side of the vehicle. 1. Open the front driver's door and remove end cap. 2. Remove center bezel. 3. Remove instrument cluster hood. 4. Remove silencer. 5. Remove wire harness connectors from Junction Block. 6. Remove Junction Block three mounting screws. 7. Remove Junction Block/BCM by pulling straight down from the mounting bayonet. 8. Disconnect BCM wire connectors and remove the assembly. 9. Remove Junction Block/BCM from vehicle. INSTALLATION - For installation, reverse the above procedures. Ensure that the wire terminals and connectors are in good condition and connectors are properly installed. BODY CONTROL MODULE REMOVAL 1. The Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. 2. Remove the two BCM attaching screws and release the two BCM locking latches from the Junction Block. 3. Disconnect BCM from the Junction Block. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 6673 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII (diagnostic read-out box) jumper wires ohmmeter voltmeter oil pressure gauge (0-300 psi) test light Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair FRONT DOOR OUTSIDE HANDLE REMOVAL 1. Remove door trim panel. 2. Close door glass. 3. Disconnect latch linkage from door latch. Fig. 33 4. Remove nuts attaching door handle to outer door panel (Fig. 33). 5. Remove door handle from vehicle. INSTALLATION 1. Place door handle into position. 2. Install nuts attaching door handle to outer door panel. 3. Connect latch linkage to door latch. 4. Open door glass. 5. Install door trim panel. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 1. Disconnect battery. 2. Disconnect main wiring harness and door opening. Window Crank 3. If equipped, remove window crank. Front Door Trim Panel 4. Disengage clips holding speaker grille to trim panel. 5. Remove screws holding door trim panel to door from around speaker opening. 6. Remove screw cap from bottom of arm rest pull cup. 7. Remove screw holding arm rest pull cup to support bracket behind trim panel. 8. Remove screw cap from behind inside door latch handle. 9. Remove screw holding door latch handle to door panel. 10. Disengage clips holding trim panel to perimeter of door. 11. Lift trim panel upward to disengage upper retainer channel. 12. Tilt top of trim panel away from door. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 6684 Door Latch Handle Rod 13. Disengage clip holding latch linkage to back of release handle. 14. Separate door trim panel from vehicle. INSTALLATION 1. Replace the clips attaching trim panel to perimeter of door. 2. Connect main harness at door opening. 3. Position door trim panel next to door. 4. Engage clip holding latch linkage to back of release handle. 5. Position door trim panel on vehicle. 6. Engage trim panel to upper retainer channel. 7. Engage clips holding trim panel to perimeter of door. 8. Install screw holding door latch handle to door panel. 9. Install screw cap from behind inside door handle. 10. Install screw holding arm rest pull cup to support bracket behind trim panel. 11. Install screw cap from bottom of arm rest pull cup. 12. Install screws holding door trim panel to door from around speaker opening. 13. Engage clips holding speaker grille to trim panel. 14. Install window crank handle, if so equipped. 15. Connect battery. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair REAR DOOR OUTSIDE HANDLE REMOVAL 1. Remove rear door trim panel. 2. Close door glass. 3. Disengage clip holding linkage to outside handle. Fig. 49 4. Remove linkage from outside handle (Fig. 49). 5. Remove nuts holding outside handle to outer door panel. 6. Remove outside door handle from vehicle. INSTALLATION 1. Position outside door handle from vehicle. 2. Install nuts attaching outside handle to outer door panel. 3. Connect linkage to outside handle (Fig. 49). 4. Connect clip holding linkage to outside handle. 5. Replace the clips attaching trim panel to perimeter of door. 6. Install rear door trim panel. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Technical Service Bulletins > Recalls for Hood Latch: > NHTSA97V095000 > Jun > 97 > Recall 97V095000: Secondary Hood Latch Spring Revised Hood Latch: Recalls Recall 97V095000: Secondary Hood Latch Spring Revised The secondary hood latch spring can disengage from its retention hole if the hood is slammed shut. If this condition occurs simultaneously without engaging the primary latch, the hood would not be restrained increasing the risk of a vehicle crash. Dealers will replace the secondary hood latch spring with a longer end hook spring. Owner Notification: Owner notification began July 14, 1997. 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 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Latch: > NHTSA97V095000 > Jun > 97 > Recall 97V095000: Secondary Hood Latch Spring Revised Hood Latch: All Technical Service Bulletins Recall 97V095000: Secondary Hood Latch Spring Revised The secondary hood latch spring can disengage from its retention hole if the hood is slammed shut. If this condition occurs simultaneously without engaging the primary latch, the hood would not be restrained increasing the risk of a vehicle crash. Dealers will replace the secondary hood latch spring with a longer end hook spring. Owner Notification: Owner notification began July 14, 1997. 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 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > Emergency Trunk Release - Availability Trunk / Liftgate Release Lever: Technical Service Bulletins Emergency Trunk Release - Availability NUMBER: 23-02-00 GROUP: Body DATE: Feb. 4, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-20-99 REV. A DATED AUGUST 13, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS INFORMATION. SUBJECT: Internal Emergency Trunk Release MODELS: 1995 - 2000 (JA) Breeze/Cirrus/Stratus 1996 - 2000 (JX) Sebring Convertible **1993 2000 (LH) Concorde/Intrepid/LHS/New Yorker/Vision/300M** 1995 - 2000 (PL) Neon NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO INSTALL AN INTERNAL EMERGENCY TRUNK RELEASE. RELEASE INSTALLATION EXPENSE IS SHARED BY DAIMLERCHRYSLER AND THE CUSTOMER. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE LABOR ONLY. THE CUSTOMER IS RESPONSIBLE FOR THE PART EXPENSE. REFER TO WARRANTY BULLETIN D-99-20 FOR CLAIMING THE LABOR EXPENSE. DISCUSSION: DaimlerChrysler Corporation is now offering internal emergency trunk releases for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the parts are available. The trunk releases are packaged in a kit containing all necessary parts and a detailed instruction sheet. PARTS REQUIRED: 1 05016812AA Kit, Emergency Trunk Release, 1995 - 2000 JA **1 05016813AA Kit, Emergency Trunk Release, 1993 - 1997 LH** 1 05016810AA Kit, Emergency Trunk Release, 1998 - 2000 LH 1 05016809AA Kit, Emergency Trunk Release, 2000 PL W/Remote Entry 1 05016811AA Kit, Emergency Trunk Release, 1994 - 1999 PL, 2000 PL W/Manual Entry 1 05016814AA Kit, Emergency Trunk Release, 1996 - 2000 JX POLICY: Customer Satisfaction Announcement TIME ALLOWANCE: Labor Operation No. 23-41-25-95 ......................................................................................................................................... .............................. 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications Cross-Member: Specifications FRONT: To Body Mounting Bolts ...................................................................................................................... ............................................ 163 Nm (120 ft. lbs.) REAR: To Body Attaching Bolts ...................................................................................................................... ................................................ 95 Nm (70 ft. lbs.) Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications > Page 6712 Cross-Member: Description and Operation This vehicle is equipped with a bolt in type rear suspension crossmember. The crossmember on this vehicle is the same for all of the optional suspensions that are available on the vehicle. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal Cross-Member: Service and Repair Removal 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove both rear wheel and tire assemblies from the vehicle. Fig. 5 3. Remove the shock absorber clevis bracket to rear knuckle attaching bolt and nut on both sides of the vehicle. 4. Remove muffler support Bracket from rear frame rail. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6715 5. Remove the rear exhaust pipe hanger from the rear suspension crossmember. Let exhaust system drop down as far as possible. 6. Position a transmission jack and wooden block under the center of the rear suspension crossmember to support and lower crossmember during removal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6716 Fig. 7 7. If vehicle is equipped with antilock brakes, remove routing clips for wheel speed sensor cable from brackets on upper control arm. 8. Remove the nuts and bolts on each side of vehicle attaching the 4 lateral links to the knuckles. 9. Remove the 4 bolts attaching the rear suspension crossmember to rear frame rails. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6717 10. Lower the rear suspension crossmember enough to access the upper control arm pivot bar to crossmember attaching bolts. Remove the 4 bolts attaching the upper control arms to the suspension crossmember. Remove the control arms from the crossmember. 11. Lower the rear suspension crossmember, lateral arms and stabilizer bar as far as possible using the transmission jack. Then with the aid of a helper remove rear suspension crossmember from the vehicle. 12. Transfer the lateral arms, stabilizer bar mounting brackets and the stabilizer bar and bushings to the replacement crossmember before installing the replacement crossmember in the vehicle. Tighten the stabilizer bar mounting bracket to rear crossmember mounting bolts to a torque of 27 Nm (20 ft. lbs.). Tighten the 4 lateral arm to crossmember attaching bolts to a torque of 95 Nm (80 ft. lbs.). Install the lateral arm to crossmember bolts so head of bolt will be toward the front of the vehicle when the crossmember is installed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6718 Cross-Member: Service and Repair Installation 1. Install the rear suspension crossmember, lateral arms and rear stabilizer bar back into the vehicle as an assembly. 2. With the aid of a helper position rear suspension crossmember back in vehicle and support it using the transmission jack. 3. Align the upper control arm pivot bars with the mounting holes in the rear suspension crossmember. Install and tighten the 4 pivot bar to crossmember attaching bolts to a torque of 107 Nm (80 ft. lbs.). 4. Using transmission jack, raise rear suspension crossmember up to the rear frame rails and loosely install the 4 attaching bolts. 5. Position a drift of the appropriate size into the positioning hole in each side of rear suspension crossmember and locating holes in the frame rail of the body. This is required to properly position rear suspension crossmember side-to-side and front to rear in the body of the vehicle. Then tighten the 4 crossmember to frame rail attaching bolts to 95 Nm (70 ft. lbs.). Remove drifts from rear suspension crossmember. 6. Align lateral links with knuckles and install the lateral arm to knuckle attaching bolts. Tighten the 4 lateral arm to spindle attaching bolts to a torque of 95 Nm (70 ft. lbs.). 7. Remove transmission jack supporting rear suspension crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6719 8. Install muffler support bracket on rear frame rail. Install rear exhaust pipe hanger on rear suspension crossmember. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6720 Fig. 7 9. If vehicle is equipped with antilock brakes, install the wheel speed sensor cable routing clip on upper control arm mounting bracket. Install and securely tighten attaching bolt. 10. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 11. Lower vehicle to the ground. 12. Check and reset if required, rear wheel alignment to meet the preferred specifications. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 6726 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. ARMING 1. Connect battery ground cable. 2. From PASSENGER side of vehicle, turn ignition switch to ON position. 3. The SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 4. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 23-30-99 > Aug > 99 > Rear Cup Holder - Comes Out Of Console Drink Holders: Customer Interest Rear Cup Holder - Comes Out Of Console NUMBER: 23-30-99 GROUP: Body DATE: Aug. 6, 1999 SUBJECT: Rear Cup Holder Slide Clip Missing OVERVIEW: This bulletin involves replacing the cup holder slide clips. MODELS: 1996 - 2000 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Cup holder came out of console and slide clips are missing out of rear cup holder assembly. DIAGNOSIS: If conditions listed above exist, perform the Repair Procedure. PARTS REQUIRED: 2 05017292AA Slide Clip, Cup Holder REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove cup holder from console. 2. Depress retaining tab and separate slide out portion of cup holder from assembly. 3. Install new side clips, p/n 05017292AA (Figure 1). 4. Install slide out portion of cup holder into assembly. 5. Install cup holder in console. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > Customer Interest for Drink Holders: > 23-30-99 > Aug > 99 > Rear Cup Holder - Comes Out Of Console > Page 6735 Labor Operation No: 23-14-35-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 23-30-99 > Aug > 99 > Rear Cup Holder Comes Out Of Console Drink Holders: All Technical Service Bulletins Rear Cup Holder - Comes Out Of Console NUMBER: 23-30-99 GROUP: Body DATE: Aug. 6, 1999 SUBJECT: Rear Cup Holder Slide Clip Missing OVERVIEW: This bulletin involves replacing the cup holder slide clips. MODELS: 1996 - 2000 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Cup holder came out of console and slide clips are missing out of rear cup holder assembly. DIAGNOSIS: If conditions listed above exist, perform the Repair Procedure. PARTS REQUIRED: 2 05017292AA Slide Clip, Cup Holder REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove cup holder from console. 2. Depress retaining tab and separate slide out portion of cup holder from assembly. 3. Install new side clips, p/n 05017292AA (Figure 1). 4. Install slide out portion of cup holder into assembly. 5. Install cup holder in console. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drink Holders: > 23-30-99 > Aug > 99 > Rear Cup Holder Comes Out Of Console > Page 6741 Labor Operation No: 23-14-35-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Service and Repair Glove Compartment Lock: Service and Repair REMOVAL 1. Remove glove box door handle. 2. Insert the proper key in lock cylinder, depress the gray locking key on back side housing at the 3 O'clock position. 3. Rotate the key clockwise to disengage cylinder from housing. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Trim Panel: Service and Repair REMOVAL AND INSTALLATION A-PILLAR SEAL REMOVAL (1) Open front door. (2) Using a fork-type tool, disengage push-in fasteners holding A-pillar seal to A-pillar. (3) Separate A-pillar seal from vehicle. INSTALLATION Reverse the preceding operation. A-PILLAR TRIM REMOVAL (1) Disengage clips holding A-pillar trim to A-pillar. (2) Separate A-pillar trim from vehicle. INSTALLATION Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Technical Service Bulletins > Customer Interest for Antenna - Keyless Entry: > 08-08-97 > Feb > 97 > Remote Keyless Entry - Inadequate/Intermittent Operation Antenna - Keyless Entry: Customer Interest Remote Keyless Entry - Inadequate/Intermittent Operation NO: 08-08-97 GROUP: Electrical DATE: Feb. 21, 1997 SUBJECT: RKE Inadequate/Intermittent Operation MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Less than expected range/reception (10 to 15 ft.) Or intermittent operation of the Remote Keyless Entry (RKE) system. DISCUSSION: The RKE system is made up of three components; transmitter, receiver, and antenna. The RKE antenna is the most likely cause of problems related to less than expected range/reception, intermittent operation, or apparent changes in operation with changes in weather. PARTS REQUIRED: 1 04897212AA Antenna, RKE AR 04318028 Tape, Vinyl Foam REPAIR PROCEDURE: This bulletin involves installing a revised RKE antenna. 1. Remove right and left instrument panel end covers. 2. Remove left A-pillar trim. 3. Remove instrument panel top cover. 4. Remove 2 bottom screws from left knee bolster panel. 5. Remove left under panel air distribution duct. 6. Remove either I/P mounting bolt from A-pillar. 7. Disconnect RKE antenna white 6-way connector (connector faces toward front of vehicle) from Body Control Module (BCM). Tape back or tie strap connector to harness. 8. Route new antenna harness, p/n 04897212AA, through gap between junction block and A-pillar. 9. Connect new antenna to BCM. 10. Route new antenna to top of I/P, wrap antenna with Mopar Vinyl Foam Tape, p/n 04318028, to prevent BSR's. Keep heat shrink wrapped portion of antenna as straight as possible along top of instrument panel when installed. 11. Secure new antenna ground eyelet under previously loosened I/P mounting bolt on A-pillar. 12. Install I/P trim panels. 13. Verify RKE operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-92-PX-90 0.4 Hrs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Technical Service Bulletins > Customer Interest for Antenna - Keyless Entry: > 08-08-97 > Feb > 97 > Remote Keyless Entry - Inadequate/Intermittent Operation > Page 6759 FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna - Keyless Entry: > 08-08-97 > Feb > 97 > Remote Keyless Entry - Inadequate/Intermittent Operation Antenna - Keyless Entry: All Technical Service Bulletins Remote Keyless Entry Inadequate/Intermittent Operation NO: 08-08-97 GROUP: Electrical DATE: Feb. 21, 1997 SUBJECT: RKE Inadequate/Intermittent Operation MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Less than expected range/reception (10 to 15 ft.) Or intermittent operation of the Remote Keyless Entry (RKE) system. DISCUSSION: The RKE system is made up of three components; transmitter, receiver, and antenna. The RKE antenna is the most likely cause of problems related to less than expected range/reception, intermittent operation, or apparent changes in operation with changes in weather. PARTS REQUIRED: 1 04897212AA Antenna, RKE AR 04318028 Tape, Vinyl Foam REPAIR PROCEDURE: This bulletin involves installing a revised RKE antenna. 1. Remove right and left instrument panel end covers. 2. Remove left A-pillar trim. 3. Remove instrument panel top cover. 4. Remove 2 bottom screws from left knee bolster panel. 5. Remove left under panel air distribution duct. 6. Remove either I/P mounting bolt from A-pillar. 7. Disconnect RKE antenna white 6-way connector (connector faces toward front of vehicle) from Body Control Module (BCM). Tape back or tie strap connector to harness. 8. Route new antenna harness, p/n 04897212AA, through gap between junction block and A-pillar. 9. Connect new antenna to BCM. 10. Route new antenna to top of I/P, wrap antenna with Mopar Vinyl Foam Tape, p/n 04318028, to prevent BSR's. Keep heat shrink wrapped portion of antenna as straight as possible along top of instrument panel when installed. 11. Secure new antenna ground eyelet under previously loosened I/P mounting bolt on A-pillar. 12. Install I/P trim panels. 13. Verify RKE operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-92-PX-90 0.4 Hrs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna - Keyless Entry: > 08-08-97 > Feb > 97 > Remote Keyless Entry - Inadequate/Intermittent Operation > Page 6765 FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > RKE Programming Keyless Entry Transmitter: Service and Repair RKE Programming Two (2) Button Transmitters TWO (2) BUTTON TRANSMITTERS To program an RKE transmitter, use the DRB and select "Body Computer", then "Miscellaneous", then "Program RKE". Push any button on the transmitter. The locks will lock or unlock to indicate that the BCM has received a useable code and will store it. If another transmitter is to be programmed, re-enter and repeat the steps. The BCM is capable of storing up to four transmitter codes. If an attempt to program a fifth transmitter is received, the DRB will inform that "All Locations Are In Use" and ask if you want to cancel them. If you answer yes, it will inform you that it is in programming mode. Press any button on a transmitter that you want to keep in memory. If you exit after answering yes, it will retain only the first transmitter code and cancel all others. Four (4) Button Transmitters FOUR (4) BUTTON TRANSMITTERS Using the DRB select "Body Computer", then "Miscellaneous" then "Program RKE". Press Lock and Decklid Release buttons simultaneously and hold for 5 seconds. All doors will unlock and will activate illuminated entry (if equipped) to indicate that the code has been programmed into the BCM's memory. Follow the same procedure for programming additional transmitters. A maximum of 4 transmitters can be programmed into the BCM at one time. If an attempt to program a fifth transmitter is received, the DRB will inform that "All Locations Are In Use" and ask if you want to cancel them. If you answer yes, it will inform you that you are in programming mode at which time you will program transmitters you want to keep in memory. If you exit after answering "Yes", it will retain only the first transmitter code and cancel all others. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > RKE Programming > Page 6770 Keyless Entry Transmitter: Service and Repair Enable/Disable Horn Chirp The DRB scan tool must be used to enable/disable the Horn Chirp. Refer to the DRB scan tool for the procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > RKE Programming > Page 6771 Keyless Entry Transmitter: Service and Repair Synchronization of Rolling Code Service The transmitter code will go out of synchronization if any button of a 4 button transmitter is pressed more than 250 times outside the range of the receiver which is inside the BCM. In other words the transmitter will not work. To synchronize the code of the particular transmitter with the receiver, press and hold both lock and decklid release buttons simultaneously for 5 seconds. Release the buttons and wait until the doors unlock indicating that the code has been synchronized. This may require waiting for as long as 6 minutes. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6776 Power Door Lock Actuator: Testing and Inspection Door Lock Motor/Latch Ensure battery is in good condition before performing the circuit tests. To determine which latch is faulty, check each individual door for electrical lock and unlock or disconnect the latch connectors one at a time, while operating the door lock switch. In the event that none of the latches work, the problem maybe caused by a short or a bad switch. Disconnecting the defective latch will allow the others to work. Front Door Lock Motor To test an individual door latch, disconnect the electrical connector from the latch. To lock the door, connect a 12 volt power source to the positive pin of the latch and a ground wire to the other pin. To unlock the door reverse the wire connections at the latch pin terminals. If these results are NOT obtained, replace the door latch assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6777 Power Door Lock Actuator: Service and Repair REMOVAL 1. Remove door trim panel. Front Door Lock Motor 2. Disconnect motor/latch wire connector. 3. Disconnect linkage from: - Outside door handle - Inside door handle - Locking knobs - Key cylinder 4. Remove motor/latch assembly attaching screws and remove assembly. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Door Lock Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Door Lock Switch Connector > Page 6782 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6783 Power Door Lock Switch: Description and Operation CIRCUIT OPERATION The door lock switches use resistors internal to the switch. There are different resistors used for the LOCK and UNLOCK functions. Both switches have the same amount of resistance for the LOCK and UNLOCK functions. When the operator selects the LOCK or UNLOCK function, from either switch, voltage is passed through the CLOSED contacts in the switch, through the appropriate resistor, to the P96 circuit for the right front door, and circuit P97 for the left front door. These circuits then connect to the Body Control Module (BCM). The BCM then process this request and supplies power and ground to the appropriate circuits. When the LOCK function is selected power is supplied on circuit P33 to all the motors. Ground is supplied on circuit P34. For the UNLOCK function the circuits are reversed. On vehicles without Vehicle Theft Security System (VTSS) all door motors are spliced together. When the vehicle is equipped with VTSS the LEFT FRONT door motor uses a separate circuit for the UNLOCK function. Circuit P55 is used to control the this function and operates the same as the P34 circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6784 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity Test Remove the switch from its mounting location. Using an ohmmeter, test door lock switch continuity and move the switch to the Lock and Unlock positions. If the resistance values are not obtained, replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6785 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Disconnect switch wire connector. 3. Remove switch attaching screws and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation Heated Element: Description and Operation SYSTEM OPERATION Heated Mirror Heated mirrors are available with Power Mirrors and Rear Window Defogger only The heated mirror is controlled by the rear window defogger switch. Only time that the heated mirror is on is when the rear window defogger is on. The mirror should become warm to the touch. CIRCUIT OPERATION The mirrors are also equipped with heating elements. These elements are activated when the operator has turned ON the rear window defogger. Circuit C16 provides power for the heaters. The C15 circuit is the power supply for the rear window defogger grid. The heated mirrors and rear window defogger switch are protected by a 10 amp fuse located in the junction block cavity 15. Grounding for the mirror heaters is provided on the Z1 circuit and terminates at the left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Testing and Inspection > Helpful Information Heated Element: Testing and Inspection Helpful Information - Check the IOD fuse located in the junction block - Circuit M1 supplies voltage to the radio, cargo lamp, dome lamp, time delay relay, glove box lamp, and vanity lamps. Check for proper operation of these items - Move the switch to its various positions and listen for the motors to click or try to move. Some movement or clicking indicates a poor connection or a mechanical problem with a mirror Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Testing and Inspection > Helpful Information > Page 6792 Heated Element: Testing and Inspection Testing 1. Using a ohmmeter, check Pin 1 of the mirror motor harness connector for continuity to ground. If OK, go to Step 2. If not OK, repair as necessary. 2. Activate the rear window defogger switch, use a voltmeter and check Pin 2 for battery voltage. a. If OK, go to Step 3. If not OK, check fuse 5 in the Junction Block and repair as necessary b. Check rear window defogger switch. If OK, go to Step 3. If not OK, replace HVAC control. c. If no voltage repair wire as necessary. 3. Remove mirror glass and check wires. If wires are OK, replace mirror glass. If not OK, repair as necessary or replace mirror. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection Power Mirror Motor: Testing and Inspection 1. Remove door trim panel. 2. Disconnect wire connector from the switch. Mirror Motor Test 3. Using two jumper wires, one connected to a 12 volt battery source, and the other connected to a good body ground. Refer to the Mirror Test for appropriate mirror response, using the mirror switch wiring harness connector. 4. If test results are not obtained as shown, check for open or shorted circuit, or replace mirror assembly as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and a left position. Moving the switch to either of these positions changes the voltage path internal to the switch (changes polarity at the motors). When the switch is moved to the LEFT position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected, the power and ground are reversed. If a LEFT door mirror movement LEFT is selected, voltage is supplied- through the P95 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected, the power and ground are reversed. When the switch is moved to the RIGHT position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected, the power and ground are reversed. If a RIGHT door mirror movement LEFT is selected, voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected, the power and ground are reversed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 6799 Power Mirror Switch: Testing and Inspection 1. Remove door trim panel. 2. Disconnect wire connector. Mirror Switch Test 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test. 4. If test results are not obtained as shown, replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 6800 Power Mirror Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Disconnect wire connector. 3. Remove attaching screws. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Fallout Damage Repair Paint: Technical Service Bulletins Paint - Fallout Damage Repair NO: 23-69-96 GROUP: Body DATE: Nov. 22, 1996 SUBJECT: Repair Of Fallout Damaged Paint MODELS: 1997 (AB) Ram Van/Wagon 1997 (AN) Dakota 1997 (BR) Ram Pickup 1997 (FJ) Sebring/Avenger/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Cirrus/Stratus/Breeze 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1997 (XJ) Cherokee 1997 (ZG) Grand Cherokee (International Market) 1997 (ZJ) Grand Cherokee NOTE: THE MOPAR FALLOUT REMOVAL KIT CAN BE USED ON ANY CURRENT OR PAST MODEL YEAR CHRYSLER VEHICLE. DISCUSSION: Mopar Parts has released a new product, Mopar Fallout Removal Kit (p/n 04882417) for correcting paint damage due to industrial fallout, rail dust, over-spray and volcanic ash. The Mopar Fallout Removal Kit does not use a compounding process or acid wash and is the current Chrysler preferred method for correcting fallout damage. This product uses a clay polymer material and a liquid that are safer and better than other fallout removal methods. The Mopar Fallout Removal Kit is easier to use and less expensive than other methods. Some vehicles that would have been repainted in the past have been saved from that time consuming and expensive process with the Mopar Fallout Removal Kit. NOTE: WHEN ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED, DISCARD THE CLAY POLYMER MATERIAL. CONTINUED USE OF THE CLAY POLYMER AFTER ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED CAN CAUSE MINOR SCRATCHING OF THE PAINT FINISH. THE AMOUNT OF FALLOUT REPAIR LIQUID PROVIDED IN THE KIT WAS ESTABLISHED BY DETERMINING THE AMOUNT OF FALLOUT THE CLAY POLYMER COULD ABSORB BEFORE IT BECAME OVER SATURATED WITH FALLOUT AND WOULD CAUSE DAMAGE TO THE PAINT FINISH. POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions Sunroof / Moonroof: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 Sunroof / Moonroof: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 Sunroof / Moonroof: Electrical Diagrams Power Sunroof NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Page 6828 Sunroof / Moonroof: Description and Operation CIRCUIT OPERATION The optional Power Sunroof is supplied power from two sources. One is the F21 circuit, which also powers the power windows. This circuit is protected by a 20 amp circuit breaker located in cavity 19 of the junction block. The circuit breaker receives its feed from the ignition switch on the A2 circuit. This circuit is HOT when the ignition switch is in the RUN position. The second power source is from the Mi circuit. This is the Ignition-Off Draw (IOD) circuit and is HOT at all times protected by a 10 amp fuse located in cavity 5 of the junction block. Ground for the power sunroof and the control module is supplied on circuit Z1. This circuit terminates at the instrument panel left side cowl. Ground for the sunroof is provided on circuit Z1. This ground terminates at the Airbag Control Module (ACM) bracket. When the operator selects the OPEN function, voltage is provided on the Q41 circuit from the control module through the CLOSED switch and to the Q44 circuit. Circuit Q44 is the switched ground back to the control module. The control module then activates the motor and moves the sunroof to the desired position. A position sensor is used to prevent the sunroof from being moved to far in any one direction. When the sensor detects the roof is at the end of its travel it sends a signal to the control module and voltage is shut off to the motor. when the operator selects the CLOSE function, voltage is provided on the Q42 circuit from the control module through the CLOSED switch and to the Q44 circuit. Circuit Q44 is the switched ground back to the control module. The control module then activates the motor and moves the sunroof to the desired position. A position sensor is used to prevent the sunroof from being moved to far in any one direction. When the sensor detects the roof is at the end of its travel it sends a signal to the control module and voltage is shut off to the motor. when the operator selects the VENT function, voltage is provided on the Q43 circuit from the control module through the CLOSED switch and to the Q44 circuit. Circuit Q44 is the switched ground back to the control module. The control module then activates the motor and moves the sunroof to the desired position. A position sensor is used to prevent the sunroof from being moved to far in any one direction. When the sensor detects the roof is at the end of its travel it sends a signal to the control module and voltage is shut off to the motor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Page 6829 Sunroof / Moonroof: Testing and Inspection - Check the 10 amp IOD fuse located in cavity 5 of the junction block - Check the 20 amp circuit breaker located in cavity 19 of the junction block - Check for a good ground at the instrument panel left side cowl Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors 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 - 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) 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 (WJ) 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 trucks 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 detailed instruction sheet. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6835 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6836 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6837 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6838 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6839 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and Inspection Power Seat Motor: Testing and Inspection Seat Motor Switch Connector 1. Remove power seat switch from seat. 2. Disconnect wire harness connector. 3. Check Pin A for battery voltage and Pin B for ground. 4. To test the seat motor and verify proper seat responses. Using two jumper wires, connect one to a battery supply and the second to a ground. Connect the other ends to the seat wire harness connector as described in the Seat Connector Chart. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch: Testing and Inspection 1. Remove switch from mounting position. Power Seat Switch 2. Using an ohmmeter, perform the Switch Continuity Tests below and refer for Pin locations. if there is no continuity at any of the switch positions, replace switch. Switch Continuity Test Switch Position = Between Continuity Off = B-N, B-J, B-M, B-E, B-K, B-L Vertical Up = B-M, B-E, A-N, A-J Vertical Down = B-N, B-J, A-M, A-E Horizontal AFT = B-K, A-L Horizontal Forward = B-L, S-K Front Tilt Up = S-J, B-E Front Tilt Down = A-E, B-J Rear Tilt Up = A-N, B-N Voltage The following test will determine whether or not voltage is continuous through the body harness to the switch. 1. Remove power seat switch from mounting position and disconnect switch from wiring harness. 2. Connect one lead of test light to Pin B of the ground terminal, and touch other test light lead to Pin A. 3. If test light comes on, harness to switch is good. if test light does not come on, perform circuit breaker test. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 6846 Power Seat Switch: Service and Repair REMOVAL 1. Remove lower recliner handle. 2. Remove screws holding seat side shield to seat frame. 3. Disconnect wiring from switch. 4. Remove screws attaching switch to seat side shield. 5. Remove switch. INSTALLATION - For installation, reverse the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 236696 > Nov > 96 > Seat Track - Adjuster Linkage Clips Broken Seat Track: Customer Interest Seat Track - Adjuster Linkage Clips Broken NO: 23-66-96 GROUP: Body DATE: Nov. 15, 1996 SUBJECT: Seat Track Adjuster Linkage Clips Broken MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus NOTE : THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH TWO WAY AND FOUR WAY MANUAL SEAT TRACKS. SYMPTOM/CONDITION: Excessive force applied to the seat adjusting bar located in the front of the seat can cause the linkage attachment clip(s) to break. If this happen the seat will not adjust when the bar is pulled. DIAGNOSIS: Visually verify linkage clips are broken; perform the Repair Procedure. PARTS REQUIRED: AR(4) 04658675 Clip, Latch Link REPAIR PROCEDURE: This bulletin involves replacing the seat adjusting bar linkage clips. Replace the seat adjusting bar linkage clips as necessary. Verify seat track operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-42-24-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 236696 > Nov > 96 > Seat Track - Adjuster Linkage Clips Broken Seat Track: All Technical Service Bulletins Seat Track - Adjuster Linkage Clips Broken NO: 23-66-96 GROUP: Body DATE: Nov. 15, 1996 SUBJECT: Seat Track Adjuster Linkage Clips Broken MODELS: 1995 - 1997 (JA) Breeze/Cirrus/Stratus NOTE : THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH TWO WAY AND FOUR WAY MANUAL SEAT TRACKS. SYMPTOM/CONDITION: Excessive force applied to the seat adjusting bar located in the front of the seat can cause the linkage attachment clip(s) to break. If this happen the seat will not adjust when the bar is pulled. DIAGNOSIS: Visually verify linkage clips are broken; perform the Repair Procedure. PARTS REQUIRED: AR(4) 04658675 Clip, Latch Link REPAIR PROCEDURE: This bulletin involves replacing the seat adjusting bar linkage clips. Replace the seat adjusting bar linkage clips as necessary. Verify seat track operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-42-24-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door Lock Switch Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door Lock Switch Connector > Page 6865 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6866 Power Door Lock Switch: Description and Operation CIRCUIT OPERATION The door lock switches use resistors internal to the switch. There are different resistors used for the LOCK and UNLOCK functions. Both switches have the same amount of resistance for the LOCK and UNLOCK functions. When the operator selects the LOCK or UNLOCK function, from either switch, voltage is passed through the CLOSED contacts in the switch, through the appropriate resistor, to the P96 circuit for the right front door, and circuit P97 for the left front door. These circuits then connect to the Body Control Module (BCM). The BCM then process this request and supplies power and ground to the appropriate circuits. When the LOCK function is selected power is supplied on circuit P33 to all the motors. Ground is supplied on circuit P34. For the UNLOCK function the circuits are reversed. On vehicles without Vehicle Theft Security System (VTSS) all door motors are spliced together. When the vehicle is equipped with VTSS the LEFT FRONT door motor uses a separate circuit for the UNLOCK function. Circuit P55 is used to control the this function and operates the same as the P34 circuit. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6867 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity Test Remove the switch from its mounting location. Using an ohmmeter, test door lock switch continuity and move the switch to the Lock and Unlock positions. If the resistance values are not obtained, replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6868 Power Door Lock Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Disconnect switch wire connector. 3. Remove switch attaching screws and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and a left position. Moving the switch to either of these positions changes the voltage path internal to the switch (changes polarity at the motors). When the switch is moved to the LEFT position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected, the power and ground are reversed. If a LEFT door mirror movement LEFT is selected, voltage is supplied- through the P95 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected, the power and ground are reversed. When the switch is moved to the RIGHT position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected, the power and ground are reversed. If a RIGHT door mirror movement LEFT is selected, voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected, the power and ground are reversed. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 6872 Power Mirror Switch: Testing and Inspection 1. Remove door trim panel. 2. Disconnect wire connector. Mirror Switch Test 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test. 4. If test results are not obtained as shown, replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 6873 Power Mirror Switch: Service and Repair REMOVAL 1. Remove door trim panel. 2. Disconnect wire connector. 3. Remove attaching screws. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch: Testing and Inspection 1. Remove switch from mounting position. Power Seat Switch 2. Using an ohmmeter, perform the Switch Continuity Tests below and refer for Pin locations. if there is no continuity at any of the switch positions, replace switch. Switch Continuity Test Switch Position = Between Continuity Off = B-N, B-J, B-M, B-E, B-K, B-L Vertical Up = B-M, B-E, A-N, A-J Vertical Down = B-N, B-J, A-M, A-E Horizontal AFT = B-K, A-L Horizontal Forward = B-L, S-K Front Tilt Up = S-J, B-E Front Tilt Down = A-E, B-J Rear Tilt Up = A-N, B-N Voltage The following test will determine whether or not voltage is continuous through the body harness to the switch. 1. Remove power seat switch from mounting position and disconnect switch from wiring harness. 2. Connect one lead of test light to Pin B of the ground terminal, and touch other test light lead to Pin A. 3. If test light comes on, harness to switch is good. if test light does not come on, perform circuit breaker test. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 6877 Power Seat Switch: Service and Repair REMOVAL 1. Remove lower recliner handle. 2. Remove screws holding seat side shield to seat frame. 3. Disconnect wiring from switch. 4. Remove screws attaching switch to seat side shield. 5. Remove switch. INSTALLATION - For installation, reverse the above procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Description and Operation Cruise Control Servo: Description and Operation SYSTEM OPERATION The servo unit consists of a solenoid valve body, and a vacuum chamber. The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Description and Operation > Page 6882 Cruise Control Servo: Testing and Inspection 1. Turn ignition switch to the ON position without starting engine. Activate speed control ON switch. Fig. 4 Servo Harness Connector 2. Disconnect the four-way electrical connector and the vacuum harness at the servo. 3. Connect a jumper wire from Pin 3 of the servo to Pin 3 of the wire connector. 4. Ground Pins 2 and 4 in the servo. Do not connect pin 1. 5. Connect a hand held vacuum pump to the vacuum nipple and apply 10 - 15 inches of vacuum. 6. If servo pulls cables, replace servo. 7. Ground Pin 1 on servo. 8. Check that the throttle cable pulls in and holds as long as the vacuum pump is connected. After one minute, check if cable is still holding. If cable does not hold replace the servo. 9. Disconnect jumper from pin 3. Cable should return to rest position. If not, replace servo. 10. Connect 4 way electrical connector and vacuum harness to servo. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Description and Operation > Page 6883 Cruise Control Servo: Service and Repair REMOVAL 1. Remove two nuts attaching speed control cable and mounting bracket to servo. 2. Remove servo from the mounting bracket. 3. Disconnect electrical connectors and vacuum hose. 4. Remove cable from throttle cam. Refer to Speed Control Servo Cable Removal/Installation. 5. Remove clip attaching cable to servo. INSTALLATION 1. Install servo cable to servo and install clip. 2. Install speed control cable to throttle cam. 3. Connect vacuum hose to servo. 4. Connect electrical connector. 5. Insert servo studs through holes in speed control cable and mounting bracket. 6. Install nuts, tighten to 7 N.m (60 in. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation SYSTEM OPERATION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 6887 Cruise Control Servo Cable: Service and Repair REMOVAL Throttle Control Shield 1. Remove throttle control shield, if equipped. 2. Remove throttle cable clasp from the throttle body cam. 3. Remove speed control cable from throttle cam by sliding clasp out hole used for throttle cable. 4. Compress the retaining tabs on the cable and slide cable out of bracket. 5. Remove 2 nuts retaining bracket to servo. 6. Remove retaining clip holding cable to servo. INSTALLATION Disconnecting Throttle Cable - Typical 1. Install retaining clip to cable at servo. 2. Slide cable bell housing over servo mounting studs. 3. Install 2 nuts at cable to servo and servo bracket, tighten to 7 N.m (60 ins. lbs.). 4. Slide cable into throttle cable bracket and engage retaining tabs. 5. Rotate the throttle cam forward to the wide open position and install speed control cable clasp. 6. Rotate the throttle cam forward to the wide open position and install throttle cable clasp. 7. Install throttle control shield, if equipped. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME/ACCELERATE, SET/COAST and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. when speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the COAST/SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the RES/ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. It, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the RES/ ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the RAM when the RES/ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the RES/ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the SET/COAST switch until the desired speed is reached. Then release the switch. The ON and OFF switches operates two components: the PCM's ON/OFF input, and the battery voltage to the brake switch, which powers the speed control servo. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 6891 Cruise Control Switch: Testing and Inspection Speed Control Switch 1. Remove the ON/OFF and CANCEL speed control switch assembly and disconnect the two-way connector. 2. Using an ohmmeter, touch a lead to each pin. The meter should read 22,848 to 22,351 ohms. Press the CANCEL button, the ohmmeter should read 0 to 0.5 ohms. Press the ON/OFF button, the ohmmeter should read 668 to 653 ohms. If the resistance does not fall within these values replace the switch. 3. Remove the SET/RESUME speed control switch assembly and disconnect the two-way connector. 4. Using an ohmmeter, touch a lead to each pin. The meter should read no continuity Press the SET button, the ohmmeter should read 1,978 to 2,022 ohms. Press the RESUME button, the ohmmeter should read 5,558 to 5,682 ohms. If the resistance do not fall within these values replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 6892 Cruise Control Switch: Service and Repair Speed Control Switch The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS . REMOVAL 1. Turn off ignition. 2. Remove two screws from side of each switch. 3. Rock switch away from airbag and steering wheel. 4. Disconnect two-way electrical connector. 5. Repeat for the other switch. INSTALLATION For installation reverse above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation Cruise Control Vacuum Reservoir: Description and Operation SYSTEM OPERATION The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Page 6896 Cruise Control Vacuum Reservoir: Service and Repair The vacuum reservoir is located on the dash panel next to the brake booster. REMOVAL 1. Remove the intake manifold. 2. Disconnect vacuum hoses from reservoir. 3. Pull vacuum reservoir from dash panel. INSTALLATION 1. Push reservoir onto dash panel. 2. Connect hoses to reservoir. 3. Install intake manifold. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME/ACCELERATE, SET/COAST and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. when speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the COAST/SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the RES/ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. It, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the RES/ ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the RAM when the RES/ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the RES/ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the SET/COAST switch until the desired speed is reached. Then release the switch. The ON and OFF switches operates two components: the PCM's ON/OFF input, and the battery voltage to the brake switch, which powers the speed control servo. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 6901 Cruise Control Switch: Testing and Inspection Speed Control Switch 1. Remove the ON/OFF and CANCEL speed control switch assembly and disconnect the two-way connector. 2. Using an ohmmeter, touch a lead to each pin. The meter should read 22,848 to 22,351 ohms. Press the CANCEL button, the ohmmeter should read 0 to 0.5 ohms. Press the ON/OFF button, the ohmmeter should read 668 to 653 ohms. If the resistance does not fall within these values replace the switch. 3. Remove the SET/RESUME speed control switch assembly and disconnect the two-way connector. 4. Using an ohmmeter, touch a lead to each pin. The meter should read no continuity Press the SET button, the ohmmeter should read 1,978 to 2,022 ohms. Press the RESUME button, the ohmmeter should read 5,558 to 5,682 ohms. If the resistance do not fall within these values replace the switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 6902 Cruise Control Switch: Service and Repair Speed Control Switch The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS . REMOVAL 1. Turn off ignition. 2. Remove two screws from side of each switch. 3. Rock switch away from airbag and steering wheel. 4. Disconnect two-way electrical connector. 5. Repeat for the other switch. INSTALLATION For installation reverse above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6911 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6917 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Service and Repair > Vehicle Speed Sensor Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair Vehicle Speed Sensor VEHICLE SPEED SENSOR 1. Raise vehicle on hoist. 2. Remove wiring connector from speed sensor. CAUTION: Clean area around speed sensor before removing. This will prevent the possibility of dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt. 4. Remove speed sensor from transaxle. CAUTION: Carefully remove vehicle speed sensor so that sensor drive gear does not fall into transaxle. Should sensor drive gear fall into the transaxle during sensor removal, drive gear must be reattached to sensor. To install, reverse removal procedure. Confirm vehicle speedometer is functioning properly following installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Service and Repair > Vehicle Speed Sensor > Page 6920 Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair Vehicle Speed Sensor Drive Gear VEHICLE SPEED SENSOR DRIVE GEAR 1. Raise vehicle on hoist. 2. Remove wiring connector from speed sensor. CAUTION: Clean area around speed sensor before removing. This will prevent the possibility of dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt. 4. Remove speed sensor from transaxle. CAUTION: Carefully remove vehicle speed sensor so that sensor drive gear does not fall into transaxle. Should sensor drive gear fall into the transaxle during sensor removal, drive gear must be reattached to sensor. 5. Remove speed sensor drive gear from speed sensor. To install, reverse removal procedure. Confirm vehicle speedometer is functioning properly following installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6929 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 6935 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > Vehicle Speed Sensor Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair Vehicle Speed Sensor VEHICLE SPEED SENSOR 1. Raise vehicle on hoist. 2. Remove wiring connector from speed sensor. CAUTION: Clean area around speed sensor before removing. This will prevent the possibility of dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt. 4. Remove speed sensor from transaxle. CAUTION: Carefully remove vehicle speed sensor so that sensor drive gear does not fall into transaxle. Should sensor drive gear fall into the transaxle during sensor removal, drive gear must be reattached to sensor. To install, reverse removal procedure. Confirm vehicle speedometer is functioning properly following installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > Vehicle Speed Sensor > Page 6938 Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair Vehicle Speed Sensor Drive Gear VEHICLE SPEED SENSOR DRIVE GEAR 1. Raise vehicle on hoist. 2. Remove wiring connector from speed sensor. CAUTION: Clean area around speed sensor before removing. This will prevent the possibility of dirt from entering the transaxle during speed sensor removal. 3. Remove speed sensor retaining bolt. 4. Remove speed sensor from transaxle. CAUTION: Carefully remove vehicle speed sensor so that sensor drive gear does not fall into transaxle. Should sensor drive gear fall into the transaxle during sensor removal, drive gear must be reattached to sensor. 5. Remove speed sensor drive gear from speed sensor. To install, reverse removal procedure. Confirm vehicle speedometer is functioning properly following installation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Service Precautions ABS Light: Service Precautions NOTE: When the Controller Antilock Brake (CAB) detects a non-functional Amber Antilock Brake System (ABS) Warning and a ABS fault is also detected at the same time which results in shutting down the ABS Brakes, then the CAB will turn on the Red Brake Warning Lamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Service Precautions > Page 6943 ABS Light: Description and Operation ANTILOCK BRAKE SYSTEM (ABS) AMBER WARNING LAMP The ABS system uses an Amber ABS Warning Lamp, located in the instrument cluster. The purpose of the warning lamp is discussed in detail below. When Detection Occurs The ABS warning lamp will turn on when the Controller Antilock Brake (CAB) detects a condition which results in a shutdown of ABS function. The ABS Warning Lamp is normally on until the CAB completes its self tests and turns the lamp off (approximately 4-5 seconds after the ignition switch is turned on). When the ABS warning lamp is on, only the ABS function of the brake system if affected. The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 Audible Warning Device: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6965 Audible Warning Device: Description and Operation CIRCUIT OPERATION Exterior Lamp-ON Warning The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Body Control Module (BCM) uses information from circuit L7 to determine if the lamps are ON, and circuit G75 for drivers door ajar. The chime function will not operate when the headlamp delay feature is active. Key-In Ignition Warning The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Body Control Module (BCM), through the CLOSED switch, to the Z14 circuit. The Z1 circuit is the ground circuit and terminates at the body ground located at the left kick panel. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G75. The BCM processes this information and turns on the chime. Funeral Mode Display Illumination The Body Control Module (BCM) controls the intensity of the instrument cluster vacuum florescent displays. This is accomplished using the input from the headlamp dimmer switch on circuit E19. When the exterior lamps are ON, and the dimmer switch is moved to the high end of it's travel, the BCM sends a message over the CCD Bus to the instrument cluster for full lamp intensity. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 6966 Audible Warning Device: Testing and Inspection This system is related to the Body Control System. For complete testing -- including Diagnostic Charts -- SEE Body Control Module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 6971 244 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 6972 245 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information Brake Warning Indicator: Description and Operation General Information Master Cylinder Fluid Level Sensor NOTE: If brake fluid level has dropped in master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. GENERAL INFORMATION The red Brake warning lamp is located in the instrument panel cluster and is used to indicate a low brake fluid condition, the parking brake is applied or that the antilock brake system has a fault but could not turn on the yellow ABS warning lamp. In addition, the brake warning lamp is turned on as a bulb check by the ignition switch when the ignition switch is placed in the crank position. Problems with this system will generally be of the type where the warning lamp fails to turn on when it should, or remains on when it should not. CIRCUIT INFORMATION The warning lamp bulb is supplied a 12 volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the park brake switch, the fluid level sensor in the master cylinder reservoir, the ignition switch in the crank position or the ABS Controller Antilock Brake. PURPOSE The Brake Fluid Level sensor is located in the brake fluid reservoir of the master cylinder assembly. The purpose of the sensor is to provide the driver with an early warning that brake fluid level in master cylinder reservoir has dropped to below normal. This may indicate an abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. As the fluid drops below the minimum level, the fluid level sensor closes the brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 6975 Brake Warning Indicator: Description and Operation ABS Warning Lamp Circuit Operation CIRCUIT OPERATION ABS Warning Lamp The ABS warning lamp is an output from the Controller Anti Lock Brake (CAB) and the ABS relay box. It is used to alert the operator of a problem in the ABS system. The G19 circuit from the CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster. Circuit G19 is also an output of the CAB to the ABS system relay contact side. Brake Warning Lamp The brake warning lamp is used to alert the operator of a problem in the vehicles braking system. This lamp also illuminates when the ignition switch is turned to the START position to perform a self check. Power for the lamp is supplied on circuit F11. This circuit is HOT when the ignition switch is in the OFF START, and RUN positions. The F11 circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. There are two switches used in this system and they are wired in parallel form. A parking brake switch, located on the parking brake mechanism, will illuminate the lamp if the normally OPEN switch is CLOSED. This switch is case grounded. The second switch used is the brake warning lamp switch. This switch in normally OPEN. When the brake system pressure is below the predetermined level the switch CLOSES and completes a path to ground. The G9 circuit is used to connect the switches to the cluster. Grounding for the brake warning lamp switch is completed on the Z1 circuit which terminates at the left strut tower. If the vehicle is built for sale in Canada the parking brake switch is used for the Daytime Running Lamp (DRL) system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > General Information > Page 6976 Brake Warning Indicator: Description and Operation Brake Warning Lamp Circuit Operation CIRCUIT OPERATION ABS Warning Lamp The ABS warning lamp is an output from the Controller Anti Lock Brake (CAB) and the ABS relay box. It is used to alert the operator of a problem in the ABS system. The G19 circuit from the CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster. Circuit G19 is also an output of the CAB to the ABS system relay contact side. Brake Warning Lamp The brake warning lamp is used to alert the operator of a problem in the vehicles braking system. This lamp also illuminates when the ignition switch is turned to the START position to perform a self check. Power for the lamp is supplied on circuit F11. This circuit is HOT when the ignition switch is in the OFF START, and RUN positions. The F11 circuit is protected by a 10 amp fuse located in cavity 11 of the junction block. There are two switches used in this system and they are wired in parallel form. A parking brake switch, located on the parking brake mechanism, will illuminate the lamp if the normally OPEN switch is CLOSED. This switch is case grounded. The second switch used is the brake warning lamp switch. This switch in normally OPEN. When the brake system pressure is below the predetermined level the switch CLOSES and completes a path to ground. The G9 circuit is used to connect the switches to the cluster. Grounding for the brake warning lamp switch is completed on the Z1 circuit which terminates at the left strut tower. If the vehicle is built for sale in Canada the parking brake switch is used for the Daytime Running Lamp (DRL) system. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 6977 Brake Warning Lamp Functional Check Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation Charge Lamp/Indicator: Description and Operation CIRCUIT OPERATION The charging system lamp is used to alert the operator that the charging system voltage has risen above or fallen below the normal operating range. When the Powertrain Control Module (PCM) determines a problem, a message is sent across the CCD Bus to the Body Control Module (BCM). The BCM processes this message and sends a signal on the CCD Bus to the instrument cluster for lamp illumination. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Cigarette Lighter: Electrical Diagrams Horn/Cigar Lighter/Power Outlet NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7002 Cigarette Lighter: Description and Operation CIRCUIT OPERATION The cigar lighter is powered by a 40 amp fuse located in the Power Distribution Center (PDC). There is also a 20 amp fuse located in cavity 8 of the junction block. When the operator presses the lighter, the contacts inside of the lighter element CLOSE, and voltage flows through the heating element to ground. Ground for the lighter is provided on the Z1 circuit and terminates at the instrument left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7003 Cigarette Lighter: Testing and Inspection - Check the 40 amp fuse located in cavity 12 of the PDC - Check the 20 amp fuse located in cavity 8 of the junction block - Check for a good ground at the instrument panel left side cowl - Check the cigar lighter element Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions Compass: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Compass: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 7027 Compass: Description and Operation SYSTEM OPERATION Compass/Temperature Mini-Trip Computer CTMC Module Compass/Temperature Mini-trip Computer The Compass/Temperature Mini-Trip Computer (CMTC) system is located on the right hand side of the instrument panel cluster. The CMTC is an electronic control module with a vacuum fluorescent display and two function buttons. The CMTC is capable of displaying compass, temperature, and trip computer information. Actuation of the STEP button will cause the CMTC to change mode of operation and actuation of the US/M button will toggle between English and Metric unit of measurement. A reset of the trip computer information is accomplished by actuating the Step and US/M buttons simultaneously. The CMTC is active only when the ignition switch is in the ON position. When the ignition switch is turned ON, the CMTC will turn on all of the segments in the display for one second then return to the last function screen that was displayed prior to the ignition being turned OFF. The functions that are available via activation of the STEP switch are as follow: Compass and Ambient Temperature - Average Trip Fuel Economy (AVG ECO) - Estimated Range (RANGE) - Present Fuel Economy (ECO) - Trip Odometer (ODO) - Elapsed Ignition On Time (ET) - Blank Screen (OFF) Compass The CMTC is an auto-calibrating compass and requires no activation of any switches to trigger a forced calibration. The compass is initially setup to be calibrated for earth fields of approximately 180 milligauss. However, due to the variation in the magnetic earth field across the country and the variation of the magnetic structure from vehicle to vehicle the compass may need to be calibrated. Refer to Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection/Procedures/Compass Calibration Service Procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 7028 Ambient Temperature The temperature is displayed in whole degrees Celsius or Fahrenheit. Temperatures greater than or equal to zero are displayed unsigned and temperatures below zero are displayed signed (-). If the temperature is more than 55 °C (131 °F) or the temperature sending line is shorted to ground, the compass and ambient temperature screen will display SC. If the temperature is less than -40 °C (-40 °F) or the temperature sending line is an open circuit, the compass and ambient temperature screen will OC. If the message CCD bus to display the ambient temperature. Mini Trip Computer Messages The Mini Trip Computer data is obtained from information put on the CCD bus from thee Powertrain Control Module and the Body Control Module. The CMTC will not display information for any of the screens for which it did not receive the proper data over the CCD bus for that particular screen. In which case the message CCD will be displayed. If the CCD message is displayed on all the screens of the CCD bus with a scan tool (DRB). If some of the screens appear to be functioning properly but some of the screens display CCD then check either the Powertrain Control Module or the Body Control Module for proper CCD bus communications. If the CCD message still persist refer to the Mini Trip Computer Self Diagnostic Test. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Component Tests and General Diagnostics Compass: Component Tests and General Diagnostics Self-Diagnostic Test The CMTC is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a scan tool (DRB) and the proper Body Diagnostic Procedures manual or by the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP button. 2. Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display Upon completion of the internal check, the CMTC will display: - PASS - FAIL - CCD If any segment of the CMTC fails to light replace the module. If FAIL is displayed, replace the module. If CCD is displayed, check the CCD and Body Control Module (BCM) for proper operation, refer to the appropriate diagnostic test procedures. If the CCD and the BCM are OK, replace the CMTC module. For additional diagnostic information on the CMTC and for identifying CMTC problems, refer to the proper Body Diagnostic Procedures. Compass Calibration Procedure Variance Settings VARIANCE SETTING PROCEDURE Variance is the difference between magnetic North and geographic North. To adjust the compass variance set the CMTC to Compass/Temperature mode and press both US/M and STEP buttons for up to one second than the symbol VAR and the current variance zone number will be displayed. Press the STEP button to select the proper variance zone as shown. After five seconds of inactivity, the displayed zone will be automatically set and normal operation in the Compass/Temperature mode resumed. DIRECT METHOD Turn the vehicle to head in either a North or South direction. The vehicle must be within 45 degrees of the North or South position or the SETTING the VARIANCE will be ignored. The vehicle may be stationary or driving at any speed for this operation. Depress the STEP button until the Compass/Temperature screen is displayed. Simultaneously press both the US/M and STEP buttons up to one second, than the symbol VAR and the current variance zone number will be displayed. Within the next five seconds momentarily press the US/M button. The variance will be set and normal operation in the Compass/Temperature mode resumed. If the US/M button is not pressed within the five seconds interval, the compass variance shall not be changed and normal operation in the Compass/Temperature mode resumed. If the VAR symbol flashes twice before resuming operation, the new zone was not accepted. Realign the vehicle to within ± 45 degrees of North or South and try again. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7031 Diagnostic Charts This system is related to the Body Control System. For complete testing -- including Diagnostic Charts -- SEE Body Control Module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Page 7032 Compass: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Remove the Cluster Hood. CMTC Module 3. With the cluster hood removed remove the four screws attaching the mini computer. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation CIRCUIT OPERATION The engine coolant temperature lamp is used to alert the operator that the coolant temperature has risen above the normal operating range. When the Powertrain Control Module (PCM) determines a problem, a message is sent across the CCD Bus to the Body Control Module (BCM). The PCM receives coolant temperature information from the engine coolant temperature sensor. This sensor uses a variable resistor to send a signal to the PCM indicating engine coolant temperature. The BCM processes this message and sends a signal on the CCD Bus to the instrument cluster for lamp illumination. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation Cruise Control Indicator Lamp: Description and Operation CIRCUIT OPERATION The CRUISE lamp is used to indicate to the operator when the vehicle speed control is engaged. The signal to illuminate the lamp is carried over the CCD Bus from the Body Control Module (BCM). The BCM receives information on vehicle speed control engagement from the PCM over the CCD Bus. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. The bulb check operation is controlled by the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 7043 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. ARMING 1. Connect battery ground cable. 2. From PASSENGER side of vehicle, turn ignition switch to ON position. 3. The SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 4. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation CIRCUIT OPERATION The dimmer control is used to control the intensity of the instrument panel lamps. It is located in the left multi-function switch. Power for the control is supplied from the L7 circuit, which is the feed for the parking lamps. This circuit is HOT when the parking lamp switch is in the ON position. Ground for the control is provided on the Z1 circuit which terminates at the instrument panel left side cowl. The control uses a variable resistor and is connected to circuit E19. Circuit E19 connects to the Body Control Module (BCM). When the operator moves the control, resistance in the circuit changes and the signal sent to the BCM changes. With the change is resistance the BCM sends a signal over the CCD Bus to the instrument panel changing the lamp intensity. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations Door/Trunk Ajar Indicator/Lamp: Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Door/Trunk Ajar Indicator/Lamp: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Page 7069 Door/Trunk Ajar Indicator/Lamp: Description and Operation CIRCUIT OPERATION The door ajar warning lamp is used to alert the operator that a door is ajar. A chime tone is used along with the lamp for an audible warning. There are four door ajar switches used. All of the switches are case grounded. The switches for the passenger door and the rear doors provide an input to the Body Control Module (BCM) on the G74 circuit. Circuit G75 is used for the drivers door. When any of the switches are grounded (door ajar), and the vehicle is moving, the Body Control Module (BCM) sends a signal over the CCD Bus to the instrument cluster for lamp illumination. The driver's door works the same as the other doors, except the switch is also used for the Key-In reminder, and the Headlamp ON chime. This feature is used to alert the operator the drivers door is ajar while the vehicle is in motion. The Body Control Module (BCM) uses information on vehicle speed from the CCD Bus and circuit G75 which connects to the drivers door ajar switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Page 7070 Door/Trunk Ajar Indicator/Lamp: Testing and Inspection This system is related to the Body Control System. For complete testing -- including Diagnostic Charts -- SEE Body Control Module. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation CIRCUIT OPERATION The Body Control Module (BCM) calculates the pointer position of the fuel gauge based on the input of the fuel tank gauge level sending unit relative to fuel tank ground. The G4 circuit sends the signal to the BCM. The fuel pump module, located in the fuel tank, contains the fuel pump and the variable resistor for the fuel gauge. Ground for the resistor is located at the left kick panel. As the position of the float arm changes, the resistor changes the current flow through the G4 circuit. The change in current flow is then measured by the BCM and the fuel gauge pointer position is adjusted to reflect the fuel tank level. The signal is sent over the CCD Bus to the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 7074 Fuel Gauge: Service and Repair REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Fuel Gauge And Temperature Gauge Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 7075 4. Remove the fuel/temperature gauge attaching screws from the housing and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications SENDING UNIT RESISTANCE -- OHMS Full (142.2 ± 4.0 mm) Nominal ............................................................................................................................................... ............................................................... 70 - Upper Limit ........................................................................................................................................ ................................................................ 90 - Lower Limit ........................................................................................................................................ ............................................................... 50 3/4 Tank (97.2 mm) Nominal ............................................................................................................................................... ............................................................. 340 - Upper Limit ........................................................................................................................................ .............................................................. 370 - Lower Limit ........................................................................................................................................ ............................................................. 310 1/2 Tank (66.1 mm) Nominal ............................................................................................................................................... ............................................................. 550 - Upper Limit ........................................................................................................................................ .............................................................. 580 - Lower Limit ........................................................................................................................................ ............................................................. 520 1/4 Tank (34.8 mm) Nominal ............................................................................................................................................... ............................................................. 760 - Upper Limit ........................................................................................................................................ .............................................................. 790 - Lower Limit ........................................................................................................................................ ............................................................. 730 Empty (0.5 ± 4.0 mm) Nominal ............................................................................................................................................... ........................................................... 1050 - Upper Limit ........................................................................................................................................ ............................................................ 1080 - Lower Limit ........................................................................................................................................ ........................................................... 1020 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 7079 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Page 7084 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). DISARMING 1. Place ignition switch in lock position. 2. Disconnect battery ground cable connector. 3. Wait at least two minutes after disconnecting battery ground cable before doing any further work on vehicle. The air bag system is designed to retain enough voltage to deploy air bag for a short time even after battery has been disconnected. ARMING 1. Connect battery ground cable. 2. From PASSENGER side of vehicle, turn ignition switch to ON position. 3. The SRS warning light should illuminate for 6 to 8 seconds, then remain off for at least 45 seconds to indicate if SRS system is functioning correctly. 4. If SRS indicator does not perform as described, refer to Air Bag Systems/Testing and Inspection. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Service and Repair Instrument Panel Circuit Board: Service and Repair REMOVAL 1. Remove six cluster back cover retaining screws and remove the cover 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Printed Circuit Board 3. Remove nine printed circuit board attaching screws and remove. There are two screws located at the base of each connector. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation CIRCUIT OPERATION When the Body Control Module (BCM) detects a low fuel condition based on the fuel level sensor input, it transmits a message across the CCD Bus to the instrument cluster to illuminate the low fuel lamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation CIRCUIT OPERATION The check engine lamp is used to indicate to the operator a problem in the engine control system. If a problem is detected, the Powertrain Control Module (PCM) sends a message, over the CCD Bus, to the Body Control Module (BCM). The BCM interprets this message and sends a signal to the instrument cluster to illuminate the lamp. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. The bulb check operation is controlled by the PCM. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation CIRCUIT OPERATION The Odometer function of the instrument cluster is controlled by the Body Control Module (BCM). To calculate the proper milage for the vehicle the BCM receives information from the Powertrain Control Module (PCM) and the Transmission Control Module (TCM) (if equipped) over the CCD Bus. It then calculates this information and sends the proper signal over the CCD Bus to the instrument cluster. Trip Odometer The trip odometer function of the instrument cluster is controlled by the Body Control Module (BCM). All information is sent across the CCD Bus. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Service and Repair > Odometer/Transmission Range Indicator Odometer: Service and Repair Odometer/Transmission Range Indicator REMOVAL 1. Remove speedometer/tachometer. Odometer/Transmision Range Indicator 2. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 7099 Odometer: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 7100 Odometer/Transmision Range Indicator 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to alert the operator that engine oil pressure has dropped below a predetermined pressure. The oil pressure switch uses a switch that CLOSES when the pressure is below the predetermined level. The switch is case grounded to the engine block. Power for the lamp is supplied on the F15 circuit. This circuit also powers the Anti-Lock lamp, located internal to the cluster, high speed fan relay, A/C Clutch relay, and the Powertrain Control Module (PCM). This circuit is protected by a 10 amp fuse located in cavity 9 of the Power Distribution Center (PDC). The ground side of the lamp is controlled by the G6 circuit. This circuit is connected from the instrument cluster to the engine oil pressure switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation CIRCUIT OPERATION Seat Belt Indicator The fasten seat belt indicator is used with the warning chime to tell the operator to fasten the seat belt. The seat belt switch is normally OPEN when the seat belt is buckled. If the seat belt is not buckled, the switch CLOSES, and a ground path is completed on the G10 circuit to the Z1 circuit. The G10 circuit is connected to the Body Control Module (BCM). When the ground path is complete a signal is sent over the CCD Bus to the instrument cluster. This illuminates the lamp in the instrument cluster. When the ignition switch is moved to the START position, the lamp is illuminated as a bulb check. Logic internal to the BCM determines the length of time the lamp remains illuminated. Seat Belt Warning The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch, located in the left B-Pillar, is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Body Control Module (BCM) and the switch. Ground for the switch is provided on circuit Z1. The Z1 circuit terminates at the deck lid ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation CIRCUIT OPERATION The dimmer control is used to control the intensity of the instrument panel lamps. It is located in the left multi-function switch. Power for the control is supplied from the L7 circuit, which is the feed for the parking lamps. This circuit is HOT when the parking lamp switch is in the ON position. Ground for the control is provided on the Z1 circuit which terminates at the instrument panel left side cowl. The control uses a variable resistor and is connected to circuit E19. Circuit E19 connects to the Body Control Module (BCM). When the operator moves the control, resistance in the circuit changes and the signal sent to the BCM changes. With the change is resistance the BCM sends a signal over the CCD Bus to the instrument panel changing the lamp intensity. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications SENDING UNIT RESISTANCE -- OHMS Full (142.2 ± 4.0 mm) Nominal ............................................................................................................................................... ............................................................... 70 - Upper Limit ........................................................................................................................................ ................................................................ 90 - Lower Limit ........................................................................................................................................ ............................................................... 50 3/4 Tank (97.2 mm) Nominal ............................................................................................................................................... ............................................................. 340 - Upper Limit ........................................................................................................................................ .............................................................. 370 - Lower Limit ........................................................................................................................................ ............................................................. 310 1/2 Tank (66.1 mm) Nominal ............................................................................................................................................... ............................................................. 550 - Upper Limit ........................................................................................................................................ .............................................................. 580 - Lower Limit ........................................................................................................................................ ............................................................. 520 1/4 Tank (34.8 mm) Nominal ............................................................................................................................................... ............................................................. 760 - Upper Limit ........................................................................................................................................ .............................................................. 790 - Lower Limit ........................................................................................................................................ ............................................................. 730 Empty (0.5 ± 4.0 mm) Nominal ............................................................................................................................................... ........................................................... 1050 - Upper Limit ........................................................................................................................................ ............................................................ 1080 - Lower Limit ........................................................................................................................................ ........................................................... 1020 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 7120 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION Brake Switch Input Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps, and is used to provide the CAB with information on when the brakes are being applied. Park Brake Switch Input Circuit G9 provides a park brake switch input to the Controller Anti-Lock Brakes (CAB). This circuit connects to cavity 14 of the CAB. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION PRNDL (Electronic) On vehicles equipped with an automatic transmission an electronic PRNDL is used to indicate to the operator gearshift position. When the ignition switch is in the OFF (unlock), RUN, or START position the Body Control Module (BCM) transmits a message over the CCD Bus instructing the instrument cluster to illuminate the proper display The BCM receives its information over the CCD Bus from the Transmission Control Module (TCM). When the ignition switch is moved to the RUN position, the BCM instructs the instrument cluster to illuminate all segments of the PRNDL as a check. PRNDL Illumination The PRNDL illumination is handled by a Light Emitting Diode (LED) and receives power on the E2 circuit from the Body Control Module (BCM). This circuit is HOT when the operator has turned the headlamp switch to the PARK or ON position. Lamp intensity is controlled by the input of the dimmer switch to the BCM on circuit E19. Ground for the LED is provided by the Z1 circuit. This circuit terminates at the instrument panel left side cowl after passing through the ground joint in the junction block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb Shift Indicator: Service and Repair Floor PRNDL Bezel Lamp Bulb The floor PRNDL bezel lamp has no service able bulb. If the lamp does not function properly, the PRNDL bezel assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb > Page 7129 Shift Indicator: Service and Repair Floor PRNDL Lamp REMOVAL 1. Remove gear shift knob. 2. Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of PRNDL bezel from floor console. 3. Pull upward carefully on PRNDL bezel and disengage tabs from rear floor console bezel. 4. Disengage wire connector to lamp assembly. 5. Separate PRNDL bezel and lamp assembly from vehicle. INSTALLATION 1. Position PRNDL and lamp assembly to vehicle. 2. Engage wire connector to lamp assembly. 3. Engage tabs on PRNDL bezel to slots in rear floor console bezel. 4. Push downward on PRNDL bezel to engage to bezel to floor console. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation CIRCUIT OPERATION The speedometer receives its information across the CCD Bus from the Body Control Module (BCM). Information on vehicle speed is transmitted from the Powertrain Control Module (PCM) across the CCD Bus to the BCM. The PCM receives its information on vehicle speed on the G7 circuit from the Transmission Control Module (TCM) on automatic transmission vehicles. On vehicles equipped with the manual transmission the vehicle speed is sent to the PCM on the G7 circuit from the Vehicle Speed Sensor (VSS), which is mounted in the transmission. The BCM calculates the position of the speedometer pointer based on the input from the PCM and adjusts the position of the gauge pointer as necessary. This signal is sent over the CCD Bus to the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 7133 Speedometer Head: Service and Repair REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Odometer/Transmision Range Indicator Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 7134 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation CIRCUIT OPERATION The tachometer receives its information across the CCD Bus from the Body Control Module (BCM). Information on engine RPM is transmitted from the Powertrain Control Module (PCM) across the CCD Bus to the BCM. The BCM calculates the position of the tachometer pointer based on the input from the PCM and adjusts the position of the gauge pointer to the necessary position. This signal is sent over the CCD Bus to the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Page 7138 Tachometer: Service and Repair REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Odometer/Transmision Range Indicator Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Page 7139 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The engine coolant temperature gauge receives its information across the CCD Bus from the Body Control Module (BCM). The engine coolant temperature sensor uses a variable resistor to send a signal to the Powertrain Control Module (PCM) indicating coolant temperature. The PCM then sends this information to the BCM across the CCD Bus. The BCM calculates the position of the engine coolant temperature gauge and based on the information received from the PCM it adjusts the position of the gauge pointer. This signal is sent over the CCD Bus to the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 7143 Temperature Gauge: Testing and Inspection At idle the temperature gauge could rise slowly to about 1/2 gauge travel. The fan will come on and the gauge could drop to about 1/3 gauge travel, this is normal. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 7144 Temperature Gauge: Service and Repair REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Fuel Gauge And Temperature Gauge Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 7145 4. Remove the fuel/temperature gauge attaching screws from the housing and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator Transmission Mode Indicator - A/T: Service and Repair Odometer/Transmission Range Indicator REMOVAL 1. Remove speedometer/tachometer. Odometer/Transmision Range Indicator 2. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 7150 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screws 1. Remove mask/lens retaining screws and remove mask/lens. Back Cover Retaining Screws 2. Disconnect odometer/transmission range indicator connector from the printed circuit board. Speedometer/Tachometer 3. Remove screws attaching speedometer/tachometer to housing and remove. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 7151 Odometer/Transmision Range Indicator 4. Remove screws attaching from the back of speedometer and remove the odometer/transmission range indicator display. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Description and Operation Backup Lamp: Description and Operation CIRCUIT OPERATION On manual transmission vehicles the back-up lamps are controlled by the back-up lamp switch on the transmission. Power for the switch is supplied on circuit F20. This circuit is protected by a 15 amp fuse located in cavity 4 of the junction block. The switch is normally OPEN. When the operator places the vehicle in REVERSE the switch CLOSES and power is passed to the L1 circuit. The L1 circuit connects between the switch and the back-up lamps. Ground for the back-up lamps is provided on circuit Z1. This circuit terminates at the deck lid ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Service and Repair > Back-Up Lamp Backup Lamp: Service and Repair Back-Up Lamp REMOVAL 1. Release trunk latch and open trunk lid. 2. Remove wing-nuts holding tail lamp to rear closure panel. 3. Separate lamp from opening in quarter panel. 4. Disengage wire connector from back of tail lamp. 5. Rotate socket counterclockwise one quarter turn. Back-Up Lamp Bulb 6. Pull socket from back of lamp. 7. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Service and Repair > Back-Up Lamp > Page 7158 Backup Lamp: Service and Repair Tail, Stop, Back Up, and Turn Signal Lamp REMOVAL 1. Release trunk latch and open trunk lid. Tail Lamp 2. Remove wing-nuts holding tail lamp to rear closure panel. 3. Separate lamp from opening in quarter panel. Tail Lamp Wire Connector 4. Disengage wire connector from back of tail lamp. 5. Separate tail lamp from vehicle. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair Brake Light Bulb: Service and Repair REMOVAL 1. Release trunk latch and open trunk lid. 2. Remove wing-nuts holding tail lamp to rear closure panel. 3. Separate lamp from opening in quarter panel. 4. Disengage wire connector from back of tail lamp. 5. Rotate socket counterclockwise one quarter turn. Tail, Stop, And Turn Signal Lamp Bulb 6. Pull socket from back of lamp. 7. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions Stop Lamp Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 7166 Stop Lamp Switch: Description and Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mounted Stop Lamp CHMSL, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 7167 Stop Lamp Switch: Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Lighting and Horns/Brake Light Switch/Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 7168 Stop Lamp Switch: Adjustments Stop Light Switch Location In Vehicle PROCEDURE 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 7169 Stop Lamp Switch: Service and Repair Stop Light Switch Location In Vehicle REMOVE 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALL NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in step Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL 1. Release trunk latch and open trunk. 2. Rotate socket counterclockwise one quarter turn. 3. Pull socket from back of lamp. Center High Mounted Stop Lamp Bulb 4. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Description and Operation Ash Tray Lamp: Description and Operation CIRCUIT OPERATION The ash receiver lamp receives power on the E2 circuit from the Body Control Module (BCM). This circuit is HOT when the operator has turned the headlamp switch to the PARK or ON position. Lamp intensity is controlled by the input of the dimmer switch to the BCM on circuit E19. Ground for the lamp is provided by the Z1 circuit. This circuit terminates at the instrument panel left side cowl after passing through the ground joint in the junction block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Service and Repair > Ash Receiver/Cup Holder Lamp Bulb Ash Tray Lamp: Service and Repair Ash Receiver/Cup Holder Lamp Bulb REMOVAL 1. Using a small, flat bladed pry tool inserted into slot in lamp bezel, release tab holding lamp to cubby bin. 2. Pull bezel and lamp assembly from cubby bin. 3. Pull lamp socket from assembly. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into lamp socket. 2. Push lamp socket into assembly. 3. Push bezel and lamp assembly into cubby bin to engage tabs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Service and Repair > Ash Receiver/Cup Holder Lamp Bulb > Page 7180 Ash Tray Lamp: Service and Repair Ash Receiver/Cup Holder Lamp REMOVAL 1. Using a small, flat bladed pry tool inserted into slot in lamp bezel, release tab holding lamp to cubby bin. 2. Pull bezel and lamp assembly from cubby bin. 3. Disengage wire connector from lamp assembly. 4. Separate lamp assembly from vehicle. INSTALLATION 1. Position lamp assembly to vehicle. 2. Engage wire connector to lamp assembly. 3. Push bezel and lamp assembly into cubby bin to engage tabs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Description and Operation Glove Box Lamp: Description and Operation CIRCUIT OPERATION The glove box lamp is powered by the 10 am fuse located in the junction block on the M1 circuit. This is the Ignition-Off Draw (IOD) fuse and is located in cavity 5. This circuit is HOT at all times. The glove box switch is normally OPEN. When the operator opens the glove box door the switch CLOSES completing a path to ground through the switch and the lamp on circuit Z1. This ground terminates at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Glove Box Lamp Glove Box Lamp: Service and Repair Glove Box Lamp REMOVAL 1. Open glove box door. 2. Pull downward on lamp/switch assembly to disengage tabs from instrument panel. 3. Disengage wire connector from assembly. 4. Separate assembly from vehicle. INSTALLATION 1. Position lamp/switch assembly from vehicle. 2. Engage wire connector to assembly. 3. Push upward on lamp/switch assembly to engage tabs holding assembly to instrument panel. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Glove Box Lamp > Page 7186 Glove Box Lamp: Service and Repair Glove Box Lamp Bulb REMOVAL 1. Open glove box door. 2. Pull downward on lamp/switch assembly to disengage tabs from instrument panel. 3. Pull bulb from socket. INSTALLATION - Push upward on lamp/switch assembly to engage tabs holding assembly to instrument panel. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation SYSTEM OPERATION - CANADA ONLY CIRCUIT OPERATION On vehicles built for sale in Canada, the headlamps operate, at reduced intensity, when the ignition switch is in the RUN position and the parking brake switch is OPEN. Power for the DRL is provided from two sources. One is a constant battery feed from the Power Distribution Center (PDC). The A3 circuit, which is protected by a 40 amp fuse in cavity 15, from the PDC feeds a 20 amp fuse located in the junction block cavity 10. From the fuse, circuit L25 supplies the direct battery voltage to the DRL. The second feed is from the F20 circuit. This circuit is HOT in the RUN position only Power for the F20 circuit is supplied by circuit A22 which connects to the ignition switch. The F20 circuit is protected by a 15 amp fuse located in cavity 4 of the junction block. Circuit G9 is the input to the DRL module on parking brake lever position. The G9 circuit connects from the DRL module to the parking brake switch. This circuit is also splices to the instrument cluster. From the DEL module, circuit L43 powers the left headlamp and circuit L34 powers the right headlamp. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation > Page 7190 Daytime Running Lamp: Testing and Inspection - Check the parking brake switch operation. - Check the 15 amp fuse in cavity 4 of the junction block. - Check the 40 amp fuse located in cavity 14, and 15 of the PDC. If this fuse is blown the headlamps will not operate. - Check the headlamp grounds located at the left strut tower and the right frame rail. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation CIRCUIT OPERATION The dimmer control is used to control the intensity of the instrument panel lamps. It is located in the left multi-function switch. Power for the control is supplied from the L7 circuit, which is the feed for the parking lamps. This circuit is HOT when the parking lamp switch is in the ON position. Ground for the control is provided on the Z1 circuit which terminates at the instrument panel left side cowl. The control uses a variable resistor and is connected to circuit E19. Circuit E19 connects to the Body Control Module (BCM). When the operator moves the control, resistance in the circuit changes and the signal sent to the BCM changes. With the change is resistance the BCM sends a signal over the CCD Bus to the instrument panel changing the lamp intensity. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation SYSTEM OPERATION Headlamp Time Delay System The optional Headlamp Time Delay system is controlled by the Body Controller (BC) and a relay located in the junction block. The headlamp time delay system can be activated by turning ON the headlamps when the engine is running, turn OFF the ignition switch, then turn OFF the headlamp switch. The BC will allow the headlamps to remain ON for 90 seconds before they automatically turn off. Refer to the Owner's Manual for more information. CIRCUIT OPERATION Headlamp Delay The headlamp delay uses a relay located in the junction block. Power for the relay is supplied on circuit A3. This circuit powers the coil and contact sides of the relay and is protected by a 40 amp fuse located in the Power Distribution Center (PDC) cavity 15. The relay is activated by the operator turning OFF the ignition with the headlamps ON. The Body Control Module (BCM) controls the ground for the coil side of the relay and the amount of time the headlamps stay ON. Circuit G50 connects the coil side of the relay to the BCM. When the relay is energized, the contacts in the relay CLOSE connecting circuits A3 and L4. Circuit L4 is used to power the fuses used for low-beam headlamp operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair REMOVAL 1. Remove lamp lens from lamp assembly by inserting a flat bladed pry tool in the slot provided in the bezel. 2. Separate lamp lens from lamp assembly. 3. Pull dome lamp bulb from socket. INSTALLATION 1. Push dome lamp bulb into socket. 2. Install lamp lens by first inserting the two tabs located opposite the lamp switch and then pushing upward on lens to engage remainder of tabs. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair REMOVAL 1. Remove fog lamp from front bumper fascia. 2. Disengage wire connector from back of fog lamp. 3. Rotate bulb base counterclockwise one quarter turn. Fog Lamp Bulb 4. Pull bulb from back of lamp. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > 10 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > 10 Way Connector > Page 7209 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation Hazard Warning Flasher: Description and Operation SYSTEM OPERATION Combination Flasher The turn signal flasher and the hazard warning flasher are combined into one unit called a combination flasher (combo-flasher). An inoperative or incomplete turn signal circuit will result in an increase in flasher speed. The flasher is mounted to the back side of the multi-function switch. CIRCUIT OPERATION Power for the hazard flashers flows from the Power Distribution Center (PDC) to the ignition switch on circuit A1. The A1 circuit is protected by a 20 amp fuse located in cavity 8. With the key in the ACCESSORY or RUN position, the ignition switch connects voltage from the A1 circuit to the A31 circuit. Circuit A31 connects to the junction block and powers fuse 15. This is a 10 amp fuse. From the fuse, circuit F13 supplies voltage to the combination flasher. The F13 circuit also supplies power to the windshield wipers and the rear window defogger relay. Circuit A15 also supplies voltage to the combination flasher. This circuit is HOT at all times and is protected by a 20 amp fuse located in cavity 6 of the PDC. The L32 circuit connects between the combination flasher and the BUS bar that powers the turn signals and the hazard flasher internal to the switch. When the hazard flashers are ON, the multi-function switch connects circuit L32 to circuits L60 and L61. It also connects circuits L91 and Z1. Circuit Z1 is the ground path for the combination flasher and terminates at the instrument panel left side cowl. Circuit L60 supplies voltage for the right side lamps and circuit L61 powers the left side lamps. These circuits also splice and supply voltage for the indicator lamps in the instrument cluster. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis Combination Flasher Diagnosis Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis > Page 7216 Hazard Warning Flasher: Testing and Inspection Helpful Information - Check the 20 amp fuses located in cavities 6, and 8 of the PDC. - Check the 10 amp fuse located in cavity 15 of the junction block. - For the left front lamp check the grounding point at the left strut tower. - For the right front lamp check the grounding point at the right frame rail. - For the left and right rear lamps check the grounding point at the deck lid ground. - Check the grounding point for the combination flasher located at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Page 7217 Hazard Warning Flasher: Service and Repair Combination Flasher Location COMBINATION FLASHER The flasher is mounted to the back side of the multi-function switch. To gain access the upper steering column cover must be removed. Refer to Steering and Suspension/Steering/Steering Column Cover removal procedures. The flasher can be removed by pulling it forward. The flasher is serviced separately from the multi-function switch. The flasher is black in color for ease of identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Multi-Function Switch 1. Remove multi-function switch. Multi-Function Switch Continuity Test 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the following continuity charts. The switch assembly is mounted center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 7221 Hazard Warning Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering and Suspension/Steering/steering column cover removal procedures. Multi-Function Switch 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION For installation, reverse the above procedures. 1. Tighten multi-function switch to column retaining screws to 2.3 N.m (20 in. lbs.) torque. 2. Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. 1. Release hood latch and open hood. 2. Remove screws holding headlamp module to radiator closure panel. 3. Separate headlamp module from radiator closure panel. Headlamp Connector 4. Disengage wire connector from back of headlamp bulb. 5. Rotate retaining ring counterclockwise one quarter turn. Headlamp Bulb Retaining Ring 6. Separate retaining ring from headlamp module. Headlamp Bulb Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 7226 7. Pull bulb from headlamp module. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Service and Repair Headlamp Control Module: Service and Repair The headlamp module contains the park and turn signal lamps and is serviced as an assembly. REMOVAL 1. Release hood latch and open hood. Headlamp Module 2. Remove screws holding headlamp module to radiator closure panel. 3. Separate headlamp module from radiator closure panel. 4. Disengage wire connector from back of head- lamp bulb. 5. Rotate Park lamp socket counterclockwise one quarter turn. 6. Pull socket from back of lamp. 7. Separate headlamp module from vehicle. INSTALLATION Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > 7 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > 7 Way Connector > Page 7234 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > 10 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > 10 Way Connector > Page 7239 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation CIRCUIT OPERATION Operation of the high beam indicator lamp is controlled by the Body Control Module (BCM). Circuit L4 provides an input to the BCM when the operator has turned ON the high beam headlamps. When the BCM receives this input in sends a message over the CCD Bus to the instrument cluster requesting lamp illumination. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation > Page 7243 Hi-Beam Indicator Lamp: Testing and Inspection - Check the 10 amp fuse located in cavity 9 of the PDC. - Check the 20 amp fuse located in cavity 7 of the junction block. - Check the 10 amp fuse located in cavity 11 of the junction block. - Check for a good ground at the instrument panel left side cowl. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Description and Operation Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a international Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the Driver Airbag Module is depressed. The horn relay is located in the Junction Block. Refer to the Junction Block label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the Junction Block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Description and Operation > Page 7248 Horn Relay: Testing and Inspection Horn Relay Location 1. Remove horn relay from the Junction Block. 2. Using ohmmeter, test between the Junction Block relay terminal 7 and ground for continuity. a. When the horn contact is not depressed, no continuity. b. Continuity to ground when horn contact is depressed. c. If continuity is not correct, repair horn contact or wiring as necessary. 3. Insert a jumper wire between terminals 8 and 10 of the horn relay in the Junction Block. a. If horns sound replace relay. b. If the horns do not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test battery voltage: a. Test Junction Block horn relay terminals 6 and 8 for voltage from fuse 8. b. If not OK, repair as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Description and Operation > Page 7249 Horn Relay: Service and Repair REMOVAL 1. Open driver's door and remove instrument panel end cover. Horn Relay Location 2. Remove horn relay. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection The horn contact consist of: - A contact switch is mounted between the Driver Airbag Module and steering wheel - The horn wire is attached to Driver Airbag Module mounting bracket. - When the Driver Airbag Module is pressed the contact ring touches the bracket mounting bolts and makes contact to ground. The ground signal is carried to the horn relay and horn sounds. Horn Contact 1. Ground horn wire. 2. If does not horn sounds check for corrosion on wire, bracket or airbag contact ring and ensure horn wire is properly connected. 3. If bracket needs to be replaced, the steering wheel must be replaced. If contact ring is bad the Driver Airbag Module must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Testing and Inspection > Page 7253 Horn Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM REMOVAL OR INSTALLATION PROCEDURES, REMOVE AND ISOLATE THE BATTERY NEGATIVE CABLE FROM THE VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable in engine compartment. 2. Remove the screws that attach the Driver Airbag Module to the steering wheel. 3. Lift the module to gain access and disconnect the squib wire. 4. Place Driver Airbag Module on a clean level surface with pad facing upward. 5. If the contact area is bad, replace Driver Airbag Module. If the mounting bracket or bushings are bad, replace steering wheel. INSTALLATION - For installation, reverse the above procedures. Use caution not to pinch wires. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions Key Cylinder Lamp: Diagram Information and Instructions Circuit Function 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. Circuit Information Wire Code Identification Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. 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. Electrostatic Discharge (ESD) Sensitive Devices Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7265 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7266 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7267 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 Key Cylinder Lamp: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Page 7276 Key Cylinder Lamp: Description and Operation The Body Control Module (BCM) controls the operation of the halo lamp upon vehicle entry. When the drivers door is opened the door ajar switch CLOSES and circuit G75 is grounded. The BCM sees that the door is ajar and provides a ground path for circuit M5O from the lamp. Power for the lamp is provided on circuit M1. This is the Ignition-Off Draw (IOD) circuit and is protected by a 10 amp fuse located in cavity 5 of the junction block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair License Plate Lamp Bulb REMOVAL 1. Remove screws holding license plate lamp to rear bumper fascia. 2. Separate license plate lamp from rear fascia. 3. Rotate socket counterclockwise one quarter turn. 4. Pull socket from back of lamp. 5. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair REMOVAL 1. Remove front reading lamp from headlining. Do not remove wire connector from lamp assembly. 2. Pull lamp reflector from lamp assembly by grasping lamp reflector opposite lamp bulbs and pulling upward. 3. Pull bulbs from socket as necessary. INSTALLATION 1. Push bulbs into sockets. 2. Push lamp reflector onto lamp assembly starting bulb end first. 3. Install front reading lamp to headlining. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Remove screws holding headlamp module to radiator closure panel. 3. Separate headlamp module from radiator closure panel. 4. Rotate socket counterclockwise one quarter turn. Park And Turn Signal Lamp Bulb 5. Pull socket from back of lamp. 6. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation SYSTEM OPERATION Headlamp Time Delay System The optional Headlamp Time Delay system is controlled by the Body Controller (BC) and a relay located in the junction block. The headlamp time delay system can be activated by turning ON the headlamps when the engine is running, turn OFF the ignition switch, then turn OFF the headlamp switch. The BC will allow the headlamps to remain ON for 90 seconds before they automatically turn off. Refer to the Owner's Manual for more information. CIRCUIT OPERATION Headlamp Delay The headlamp delay uses a relay located in the junction block. Power for the relay is supplied on circuit A3. This circuit powers the coil and contact sides of the relay and is protected by a 40 amp fuse located in the Power Distribution Center (PDC) cavity 15. The relay is activated by the operator turning OFF the ignition with the headlamps ON. The Body Control Module (BCM) controls the ground for the coil side of the relay and the amount of time the headlamps stay ON. Circuit G50 connects the coil side of the relay to the BCM. When the relay is energized, the contacts in the relay CLOSE connecting circuits A3 and L4. Circuit L4 is used to power the fuses used for low-beam headlamp operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Service and Repair Headlamp Control Module: Service and Repair The headlamp module contains the park and turn signal lamps and is serviced as an assembly. REMOVAL 1. Release hood latch and open hood. Headlamp Module 2. Remove screws holding headlamp module to radiator closure panel. 3. Separate headlamp module from radiator closure panel. 4. Disengage wire connector from back of head- lamp bulb. 5. Rotate Park lamp socket counterclockwise one quarter turn. 6. Pull socket from back of lamp. 7. Separate headlamp module from vehicle. INSTALLATION Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a international Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the Driver Airbag Module is depressed. The horn relay is located in the Junction Block. Refer to the Junction Block label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the Junction Block until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation > Page 7299 Horn Relay: Testing and Inspection Horn Relay Location 1. Remove horn relay from the Junction Block. 2. Using ohmmeter, test between the Junction Block relay terminal 7 and ground for continuity. a. When the horn contact is not depressed, no continuity. b. Continuity to ground when horn contact is depressed. c. If continuity is not correct, repair horn contact or wiring as necessary. 3. Insert a jumper wire between terminals 8 and 10 of the horn relay in the Junction Block. a. If horns sound replace relay. b. If the horns do not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test battery voltage: a. Test Junction Block horn relay terminals 6 and 8 for voltage from fuse 8. b. If not OK, repair as necessary. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Description and Operation > Page 7300 Horn Relay: Service and Repair REMOVAL 1. Open driver's door and remove instrument panel end cover. Horn Relay Location 2. Remove horn relay. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions Stop Lamp Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 7305 Stop Lamp Switch: Description and Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mounted Stop Lamp CHMSL, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 7306 Stop Lamp Switch: Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Lighting and Horns/Brake Light Switch/Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 7307 Stop Lamp Switch: Adjustments Stop Light Switch Location In Vehicle PROCEDURE 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Service Precautions > Page 7308 Stop Lamp Switch: Service and Repair Stop Light Switch Location In Vehicle REMOVE 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALL NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in step Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > 10 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > 10 Way Connector > Page 7313 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Multi-Function Switch 1. Remove multi-function switch. Multi-Function Switch Continuity Test 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the following continuity charts. The switch assembly is mounted center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 7317 Hazard Warning Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering and Suspension/Steering/steering column cover removal procedures. Multi-Function Switch 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION For installation, reverse the above procedures. 1. Tighten multi-function switch to column retaining screws to 2.3 N.m (20 in. lbs.) torque. 2. Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > 7 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > 7 Way Connector > Page 7322 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > 10 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > 10 Way Connector > Page 7327 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection Horn Switch: Testing and Inspection The horn contact consist of: - A contact switch is mounted between the Driver Airbag Module and steering wheel - The horn wire is attached to Driver Airbag Module mounting bracket. - When the Driver Airbag Module is pressed the contact ring touches the bracket mounting bolts and makes contact to ground. The ground signal is carried to the horn relay and horn sounds. Horn Contact 1. Ground horn wire. 2. If does not horn sounds check for corrosion on wire, bracket or airbag contact ring and ensure horn wire is properly connected. 3. If bracket needs to be replaced, the steering wheel must be replaced. If contact ring is bad the Driver Airbag Module must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection > Page 7331 Horn Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM REMOVAL OR INSTALLATION PROCEDURES, REMOVE AND ISOLATE THE BATTERY NEGATIVE CABLE FROM THE VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable in engine compartment. 2. Remove the screws that attach the Driver Airbag Module to the steering wheel. 3. Lift the module to gain access and disconnect the squib wire. 4. Place Driver Airbag Module on a clean level surface with pad facing upward. 5. If the contact area is bad, replace Driver Airbag Module. If the mounting bracket or bushings are bad, replace steering wheel. INSTALLATION - For installation, reverse the above procedures. Use caution not to pinch wires. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > 7 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > 7 Way Connector > Page 7336 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7337 Turn Signal Switch: Testing and Inspection Multi-Function Switch 1. Remove multi-function switch. Multi-Function Switch Continuity Test 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the following continuity charts. The switch assembly is mounted center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7338 Turn Signal Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering and Suspension/Steering/steering column cover removal procedures. Multi-Function Switch 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION For installation, reverse the above procedures. 1. Tighten multi-function switch to column retaining screws to 2.3 N.m (20 in. lbs.) torque. 2. Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair REMOVAL 1. Release trunk latch and open trunk lid. 2. Remove wing-nuts holding tail lamp to rear closure panel. 3. Separate lamp from opening in quarter panel. 4. Disengage wire connector from back of tail lamp. 5. Rotate socket counterclockwise one quarter turn. Tail, Stop, And Turn Signal Lamp Bulb 6. Pull socket from back of lamp. 7. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation Trunk Lamp: Description and Operation CIRCUIT OPERATION The trunk lamp uses a switch located in the trunk latch which is case grounded. The switch is normally OPEN. When the trunk is opened, the switch CLOSES, completing a path to ground. The M1 circuit provides power to the lamp, and is HOT at all times. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation > Page 7346 Trunk Lamp: Testing and Inspection - Check the 10 amp fuse located in cavity 5 of the PDC. - Check for a good ground located at the instrument panel left side cowl. - Check the door switches for a good ground. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation Turn Signal Flasher: Description and Operation GENERAL INFORMATION Multi-Function Switch WARNING: ON VEHICLES EQUIPPED WITH AIRBAG, SEE AIR BAGS AND SEAT BELTS/AIR BAGS FOR AIRBAG REMOVAL PROCEDURES. Multi-Function/Exterior Lamp Switch The multi-function switch contains: Turn signals - Hazard warning - Headlamps - Headlamp beam select - Parking lamps - Panel dimmer - Fog Lamp - Headlamp optical horn - Windshield wiper - Pulse wipe - Mist wipe - Windshield washer switches. The multi-function switch is mounted center of the steering column. There are two levers one on each side of the steering column. The left side controls the signaling and lighting. The right side controls the windshield wiper and washer system. When the driver wishes to signal his intentions to change direction of travel, he moves the left lever upward to cause the right signals to flash and downward to cause the left signals to flash. After completion of a turn the system is deactivated automatically. As the steering wheel returns to the straight ahead position the turn signals are canceled. A canceling cam is molded to the clockspring mechanism which comes in contact with the cancel actuator on the multi-function switch. The canceling cam lobe pushes on the cancel actuator and returns the switch to the off position. If only momentary signaling such as indication of a lane change is desired, the switch is actuated to a left or right intermediate detent position. in this position the signal lamps flash as described above, but the switch returns to the OFF position as soon as the lever is released. SYSTEM OPERATION Combination Flasher The turn signal flasher and the hazard warning flasher are combined into one unit called a combination flasher (combo-flasher). An inoperative or incomplete turn signal circuit will result in an increase in flasher speed. The flasher is mounted to the back side of the multi-function switch. Exterior Lamps To turn lamps ON: Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7351 - Parking lamps, using left stalk turn headlamp switch to the first detent - Headlamps, turn switch to second detent - Headlamp beam select, from low beam to high beam or high to low, pull left stalk towards steering wheel. The ignition switch must be in the RUN position for the instrument panel high beam indicator to light. - Headlamp optical horn, pull left stalk towards steering wheel, headlamps will stay ON as long as stalk is held. - Fog lamps, pull switch outward with headlamps on low beam - Panel dimmer, rotating dimmer switch regulates density of the instrument panel illumination. There are nine detentes (steps) of density. Detent 1 is full brightness and each detent thereafter is lower. Testing the dimmer switch using the continuity test, the resistance value is measured for each detent. Detents 3 through 8 are measured in equal graduations, up or down and referred to as linear. Example: if detent 3 was 5 ohms and detent 4 was 7 ohms detent 5 should be 9 ohms. Hazard Warning System The hazard warning system is actuated by a push button located on the top of the steering column between the steering wheel and the instrument panel. The hazard switch is identified with a double triangle on top of the button. Push and release the button to turn the hazard function ON or OFF. The button will move out from the steering column in the ON position and will remain in toward the column in the OFF position. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7352 Combination Flasher Diagnosis Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7353 Turn Signal Flasher: Service and Repair Combination Flasher Location COMBINATION FLASHER The flasher is mounted to the back side of the multi-function switch. To gain access the upper steering column cover must be removed. Refer to Steering and Suspension/Steering/Steering Column Cover removal procedures. The flasher can be removed by pulling it forward. The flasher is serviced separately from the multi-function switch. The flasher is black in color for ease of identification. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation CIRCUIT OPERATION Right And Left Turn Signal Indicators These lamps are used to indicate to the operator which turn signal is ON. Power for the lamps is supplied from the turn signal switch. The L60 circuit is used for the right turn indicator, and the L61 is used for the left turn indicator. Ground for the lamps is provided on the Z1 circuit and terminates at the instrument panel left side cowl panel. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb Turn Signal Bulb: Service and Repair Park and Turn Signal Lamp Bulb REMOVAL 1. Release hood latch and open hood. 2. Remove screws holding headlamp module to radiator closure panel. 3. Separate headlamp module from radiator closure panel. 4. Rotate socket counterclockwise one quarter turn. Park And Turn Signal Lamp Bulb 5. Pull socket from back of lamp. 6. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb > Page 7362 Turn Signal Bulb: Service and Repair Tail/Stop and Turn Signal Lamp Bulb REMOVAL 1. Release trunk latch and open trunk lid. 2. Remove wing-nuts holding tail lamp to rear closure panel. 3. Separate lamp from opening in quarter panel. 4. Disengage wire connector from back of tail lamp. 5. Rotate socket counterclockwise one quarter turn. Tail, Stop, And Turn Signal Lamp Bulb 6. Pull socket from back of lamp. 7. Pull bulb from socket. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > 7 Way Connector Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > 7 Way Connector > Page 7367 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7368 Turn Signal Switch: Testing and Inspection Multi-Function Switch 1. Remove multi-function switch. Multi-Function Switch Continuity Test 2. Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the following continuity charts. The switch assembly is mounted center of the steering column. Should any function of the switch fail, the entire switch assembly must be replaced. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7369 Turn Signal Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering and Suspension/Steering/steering column cover removal procedures. Multi-Function Switch 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION For installation, reverse the above procedures. 1. Tighten multi-function switch to column retaining screws to 2.3 N.m (20 in. lbs.) torque. 2. Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Description and Operation Vanity Lamp: Description and Operation CIRCUIT OPERATION The visor/vanity lamps are operated by a switch internal to the assembly. Power for the lamps is provided by circuit M1. The M1 circuit is spliced and provides power to both lamps and is HOT at all times. When the operator lifts the cover on the lamp, the switch CLOSES, completing a path to ground on circuit Z1. This circuit terminates at the instrument panel left side cowl after passing through the ground joint in the junction block. On vehicles equipped with the optional garage door opener the ground circuit is changed from Z1 to G38. The G38 circuit connects from the lamps to the Body Control Module (BCM). This input to the BCM allows for a garage door opener lock-out feature. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass Element Relay > Component Information > Testing and Inspection Heated Glass Element Relay: Testing and Inspection 1. Check fuses. a. Fuse 15 in the Junction Block b. Fuse 8 and 12 in the Power Distribution Center. Rear Window Defogger Relay (EBL) 2. Remove the rear window defogger relay EBL. from the Junction Block. 3. Using voltmeter, test battery voltage: a. Test rear window defogger relay terminals 11 for battery voltage. If voltage is OK, go to Step 2. If voltage is not OK, repair A4 circuit. b. Test rear window defogger relay terminals 15 for battery voltage. If voltage is OK, go to Step 3. If voltage is not OK, repair circuit between terminal 15 and fuse 15 in the Junction Block. c. Use a known good relay. If not OK, repair circuits as necessary. If OK, replace relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass Element Relay > Component Information > Testing and Inspection > Page 7378 Heated Glass Element Relay: Service and Repair REMOVAL 1. Open the driver's door and remove instrument panel end cover. Rear Window Defogger Relay (EBL) 2. Remove rear window defogger relay from the Junction Block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Customer Interest: > 08-06-98 > Feb > 98 > A/C - EBL Indicator Bulb Does Not Light Rear Defogger: Customer Interest A/C - EBL Indicator Bulb Does Not Light NO: 08-06-98 GROUP: Electrical DATE: Feb. 27, 1998 SUBJECT: "EBL" indicator Bulb Does Not Light THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-38-96 DATED NOVEMBER 8, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THE 1998 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH **ASTERISKS". MODELS: 1995 - **1998** (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Electric Back Light (EBL) indicator bulb in the HVAC control module does not light, but defogger grid functions normally. DIAGNOSIS: Use the following steps to diagnose this condition: 1. Verify the indicator bulb does not light and the defogger grid functions normally. 2. Check fuse # 6 in the junction block (fuse # 6 powers the indicator light and the heated rear view mirrors). If fuse # 6 is improperly installed, missing or blown, repair or replace as necessary. 3. If fuse # 6 is OK (heated rear view mirrors function) check that the 8-way connector is properly installed In the back of the HVAC control module. 4. If the 8-way connector is installed properly perform the diagnosis on page 8N-1 of the 1997 Breeze/Cirrus/Stratus service manual (Publication No. 81-270-7121). POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 08-06-98 > Feb > 98 > A/C - EBL Indicator Bulb Does Not Light Rear Defogger: All Technical Service Bulletins A/C - EBL Indicator Bulb Does Not Light NO: 08-06-98 GROUP: Electrical DATE: Feb. 27, 1998 SUBJECT: "EBL" indicator Bulb Does Not Light THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-38-96 DATED NOVEMBER 8, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THE 1998 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH **ASTERISKS". MODELS: 1995 - **1998** (JA) Breeze/Cirrus/Stratus SYMPTOM/CONDITION: Electric Back Light (EBL) indicator bulb in the HVAC control module does not light, but defogger grid functions normally. DIAGNOSIS: Use the following steps to diagnose this condition: 1. Verify the indicator bulb does not light and the defogger grid functions normally. 2. Check fuse # 6 in the junction block (fuse # 6 powers the indicator light and the heated rear view mirrors). If fuse # 6 is improperly installed, missing or blown, repair or replace as necessary. 3. If fuse # 6 is OK (heated rear view mirrors function) check that the 8-way connector is properly installed In the back of the HVAC control module. 4. If the 8-way connector is installed properly perform the diagnosis on page 8N-1 of the 1997 Breeze/Cirrus/Stratus service manual (Publication No. 81-270-7121). POLICY: Information Only Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 26-06-97P > Jun > 97 > A/C - Rear Defogger Diagnostic Procedures Revision Rear Defogger: All Technical Service Bulletins A/C - Rear Defogger Diagnostic Procedures Revision NUMBER: 26-06-97P GROUP: Miscellaneous DATE: June, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 JA/JX Body Diagnostic Manual - Publication Number 81-699-96031 DESCRIPTION OF CHANGES Revisions to the diagnostic procedures Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 26-06-97P > Jun > 97 > A/C - Rear Defogger Diagnostic Procedures Revision > Page 7396 284 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 26-06-97P > Jun > 97 > A/C - Rear Defogger Diagnostic Procedures Revision > Page 7397 285 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Defogger: > 26-06-97P > Jun > 97 > A/C - Rear Defogger Diagnostic Procedures Revision Rear Defogger: All Technical Service Bulletins A/C - Rear Defogger Diagnostic Procedures Revision NUMBER: 26-06-97P GROUP: Miscellaneous DATE: June, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 JA/JX Body Diagnostic Manual - Publication Number 81-699-96031 DESCRIPTION OF CHANGES Revisions to the diagnostic procedures Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Defogger: > 26-06-97P > Jun > 97 > A/C - Rear Defogger Diagnostic Procedures Revision > Page 7403 284 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Defogger: > 26-06-97P > Jun > 97 > A/C - Rear Defogger Diagnostic Procedures Revision > Page 7404 285 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection Heated Glass Element Relay: Testing and Inspection 1. Check fuses. a. Fuse 15 in the Junction Block b. Fuse 8 and 12 in the Power Distribution Center. Rear Window Defogger Relay (EBL) 2. Remove the rear window defogger relay EBL. from the Junction Block. 3. Using voltmeter, test battery voltage: a. Test rear window defogger relay terminals 11 for battery voltage. If voltage is OK, go to Step 2. If voltage is not OK, repair A4 circuit. b. Test rear window defogger relay terminals 15 for battery voltage. If voltage is OK, go to Step 3. If voltage is not OK, repair circuit between terminal 15 and fuse 15 in the Junction Block. c. Use a known good relay. If not OK, repair circuits as necessary. If OK, replace relay. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Page 7409 Heated Glass Element Relay: Service and Repair REMOVAL 1. Open the driver's door and remove instrument panel end cover. Rear Window Defogger Relay (EBL) 2. Remove rear window defogger relay from the Junction Block. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Master Window Switch Passenger Window Switch Continuity Test For switch testing, remove the switch from its mounting. Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 7414 Power Window Switch: Service and Repair REMOVAL Master Switch 1. Remove driver's door trim panel. 2. Remove three mounting screws. 3. Remove switch and disconnect wire connector. Passenger Switch 1. Remove passenger door trim panel. 2. Disconnect switch wire connector. 3. Remove switch from bezel. INSTALLATION Master Switch and Passenger Switch For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Testing and Inspection Power Window Motor: Testing and Inspection 1. Remove door trim panel. 2. Connect positive (+) lead from a test battery to either of the two motor terminals. 3. Connect negative (-) lead from test battery to remaining motor terminal. 4. The motor should now rotate in one direction to either move window up or down. a. If window happens to already be in full UP position and motor is connected so as to move it in UP direction no movement will be observed. b. Likewise, motor connected to move window in DOWN direction no movement will be observed if window is already in full DOWN position. c. Reverse battery leads in Step 1 and Step 2 and window should now move. If window does not move, remove motor. 5. If window moved completely up or down, the test leads should be reversed one more time to complete a full window travel inspection. 6. If window does not move, check to make sure that it is free. 7. It is necessary that the window be free to slide up and down in the glass channels. If the window is not free to move up and down, the window lift motor will not be able to move the glass. 8. To determine if the glass is free is to disconnect the regulator from the glass lift plate. Remove the two attaching screws, and slide the window up and down by hand. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Testing and Inspection > Page 7419 Power Window Motor: Service and Repair WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN SECTOR GEAR AREA WHERE THEY CAN BE PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE. REMOVAL 1. Move the window to the full-up position, if possible. 2. Remove door trim panel and window regulator. WARNING: FAILURE TO CLAMP THE SECTOR GEAR TO THE MOUNTING PLATE WHEN REMOVING THE MOTOR CAN RESULT IN INJURY. 3. Disconnect wiring connector from motor. 4. Secure the sector gear and mounting plate with a C clamp or similar clamping tool. This will prevent a sudden and forceful movement of the regulator when the motor is removed. Motor Removal 5. Remove three mounting screws that hold motor gearbox to regulator. 6. Remove motor from regulator. INSTALLATION 1. Install new motor on regulator by positioning motor gearbox so that it engages regulator sector teeth. 2. A slight rotational or rocking movement may be necessary to bring three motor gearbox screw holes into proper position. 3. Install three gearbox screws and one tie down bracket screw, if applicable. Tighten to 5.6 to 8 N.m (50 to 70 in.lbs.) torque. 4. Install regulator, using the switch, test operation of motor. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Master Window Switch Passenger Window Switch Continuity Test For switch testing, remove the switch from its mounting. Using an ohmmeter, refer to Window Switch Continuity Charts to determine if continuity is correct. If the results are not obtained, replace the switch. The master window switch has an Auto-Down feature. Actuation of the master switch to the second down position will move the drivers side window completely down. The electronic switch will automatically disconnect the motor approximately 1 second after the window bottoms out. Failure of the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13 seconds. The auto down function can be canceled by any movement of that switch. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 7423 Power Window Switch: Service and Repair REMOVAL Master Switch 1. Remove driver's door trim panel. 2. Remove three mounting screws. 3. Remove switch and disconnect wire connector. Passenger Switch 1. Remove passenger door trim panel. 2. Disconnect switch wire connector. 3. Remove switch from bezel. INSTALLATION Master Switch and Passenger Switch For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7429 Wiper Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7430 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7431 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7432 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 7437 Windshield Washer Switch: Testing and Inspection Windshield Washer Diagnosis Whenever a windshield washer malfunction occurs, first verify that the windshield washer wire harness is properly connected to all connectors before starting normal diagnosis and repair procedures. Refer to Windshield Washer Diagnosis Chart. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7441 Wiper Switch: Service and Repair MULTI-FUNCTION SWITCH REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering and Suspension/Steering/steering column cover removal procedures. Multi-Function Switch Mounting 3. Remove multi-function switch mounting screws. 4. Disconnect wire connectors. Lift the switch straight up to remove. INSTALLATION For installation, reverse the above procedures. 1. Tighten multi-function switch to column retaining screws to 2.3 N.m (20 in. lbs.) torque. 2. Tighten steering column cover retaining screws to 2 N.m (17 in. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7445 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7446 Windshield Washer Pump: Service and Repair REMOVAL 1. Partially remove the bumper facia as needed to gain access to the reservoir pump. 2. Place a drain bucket below the reservoir to catch any washer solvent that may leak out. Washer Pump 3. Firmly grasping pump by hand twist and pull away from reservoir and out of grommet. Care must be taken not to puncture reservoir. 4. Remover rubber grommet from reservoir and throw away INSTALLATION - For installation, reverse the above procedures. A new grommet is required for installation. Refill reservoir with the washer solvent. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect washer fluid hose at in-line connector on top of the right shock tower. 2. Partially remove bumper facia as needed to gain access to the reservoir. 3. Remove carbon canister. Reservoir Removal 4. Disconnect wire connector from washer pump and harness mounting tab. 5. Slide rearward and drop down and away from vehicle. 6. Drain washer fluid from reservoir into an appropriate container. 7. Disconnect the washer hose from the reservoir. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair Windshield Washer Spray Nozzle: Service and Repair REMOVAL To replace nozzle, disconnect washer fluid hose. Using a needle nose pliers, squeeze together the locking tabs on the nozzle. Washer Fluid Hose Location INSTALLATION For installing make sure that both locking tabs are securely snapped into position. Connect washer fluid hose. If no washer spray, check fluid hoses kinks or leaks. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 7456 Windshield Washer Switch: Testing and Inspection Windshield Washer Diagnosis Whenever a windshield washer malfunction occurs, first verify that the windshield washer wire harness is properly connected to all connectors before starting normal diagnosis and repair procedures. Refer to Windshield Washer Diagnosis Chart. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments High speed, wet windshield operation, the right blade tip may override the cowl screen slightly. This is normal and should not affect wiper system performance. 1. Lift arms and blade assemble to a over centered position. 2. Turn ignition switch to ON or ACC position. 3. Use LOW speed setting and cycle the wiper motor to the PARK position. 4. Turn ignition OFF. 5. Carefully lower arm and blades to the windshield. 6. Measure the distance from the blade tip to the cowl screen edge. The blade should be 18 to 42 mm (0.75 to 1.60 ins.). 7. If not OK, check for worn parts. Arm Adjustment 8. In the event the blade tip strikes the cowl screen or molding remove arm. Remove metal keyway from the pivot shaft by cutting or breaking it off. File the surface smooth. Position arm on windshield and tighten to 37 to 43 N.m (27 to 32 ft. lbs.) torque. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm and Blade Wiper Arm: Service and Repair Wiper Arm and Blade REMOVAL 1. Place the wiper arm/blades in the PARK position and turn ignition OFF. 2. Unsnap arm cover. By hand rock gently side to side and slide away from arm pivot. To remove the left side raise hood for clearance 3. Loosen retention nut. 4. Remove the arm from the pivot by using a universal claw puller or by hand rock gently side to side and slide. Raise blade and arm off glass and rock side to side while applying pressure with the puller till loose. Ensure that the puller is not on the collar below the arm. 5. Remove arm retention nut and arm. INSTALLATION 1. Place arm on pivot shaft, align arm with key- way and push down on arm to start on pivot shaft. 2. Start retention nut. 3. Raise arm and blade off windshield while tightening retention nut. Tighten nut to 37 to 43 N. mm (27 to 32 ft.lbs.). 4. Install arm head cover. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm and Blade > Page 7462 Wiper Arm: Service and Repair Wiper Arm Linkage or Cap REMOVAL 1. Remove wiper arms and blades. 2. Remove the cowl screen. 3. Remove wiper motor assembly. Linkage Removal 4. Disconnect wiper arm linkage, by using an ball joint/tie rod separator, separate the right and left ball cap from the ball. 5. Disconnect drive link from the motor crank. Using an ball joint/tie rod separator and separate the ball cap from the ball. INSTALLATION - For installation, reverse the above procedures. Align link ball cap over ball and gently press fit against shoulder of cap to lock cap into position. If motor output crank nut was removed, tighten nut to 25 to 30 N.m (19 to 23 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) 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 Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7476 Wiper Blade: Testing and Inspection Cleaning and Inspection Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner. If the wiper blades continue to streak or smear, they should be replaced. The wiper blade should run smoothly across the windshield in both directions. The wiper blade should slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over center. If this condition exists, refer to the Wiper/Arm/Wiper Arm Alignment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection Wiper Blade: Service and Repair Cleaning and Inspection Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner. If the wiper blades continue to streak or smear, they should be replaced. The wiper blade should run smoothly across the windshield in both directions. The wiper blade should slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over center. If this condition exists, refer to the Wiper/Arm/Wiper Arm Alignment. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7479 Wiper Blade: Service and Repair Wiper Arm and Blade REMOVAL 1. Place the wiper arm/blades in the PARK position and turn ignition OFF. 2. Unsnap arm cover. By hand rock gently side to side and slide away from arm pivot. To remove the left side raise hood for clearance 3. Loosen retention nut. 4. Remove the arm from the pivot by using a universal claw puller or by hand rock gently side to side and slide. Raise blade and arm off glass and rock side to side while applying pressure with the puller till loose. Ensure that the puller is not on the collar below the arm. 5. Remove arm retention nut and arm. INSTALLATION 1. Place arm on pivot shaft, align arm with key- way and push down on arm to start on pivot shaft. 2. Start retention nut. 3. Raise arm and blade off windshield while tightening retention nut. Tighten nut to 37 to 43 N. mm (27 to 32 ft.lbs.). 4. Install arm head cover. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7480 Wiper Blade: Service and Repair Wiper Blade REMOVAL 1. Turn wiper switch ON, position blades to a convenient place on the windshield by turning the ignition switch ON and OFF Turn ignition switch OFF, when blade is in the desirable position. 2. Lift wiper arm to raise blade off glass. Wiper Blade And Element Remove Blade From Arm 3. Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip. Wiper Blade - Typical 4. The driver's side wiper blade has a air foil on it and the air foil points downward. 5. Gently place wiper arm tip on windshield. INSTALLATION - For installation reverse the above procedures. When complete turn ignition switch ON. Turn wiper switch OFF allowing the wiper blades PARK, Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7481 then turn ignition switch OFF. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7482 Wiper Blade: Service and Repair Wiper Blade Element REMOVAL 1. Lift wiper arm to raise blade off the windshield. Wiper Blade And Element Remove Blade From Arm 2. Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip. Gently place wiper arm tip on windshield. Wiper Blade And Element Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Cleaning and Inspection > Page 7483 3. Remove wiping rubber element by pulling stopper of the rubber element, out of the claws of blade assemble. The wiper rubber element and two vertebra will be removed. INSTALLATION 1. Slide the rubber element into the blade assembly through the claws. 2. Slide the metal vertebra into the top element slot, with the vertebra curved to match the windshield 3. Ensure that the final blade claw is locked into the slot at the end of the rubber element. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 7487 Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 7488 Wiper Motor: Testing and Inspection Wiper Motor Test WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, SEE AIR BAGS AND SEAT BELTS/AIR BAGS FOR STEERING WHEEL OR COLUMN REMOVAL PROCEDURES. Whenever a wiper motor malfunction occurs, disconnect motor wire harness and clean the terminals. Ensure the wire harness is properly connected before starting diagnosis and repair procedures. Refer to Wiper Motor Test. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Replacement Wiper Motor: Service and Repair Replacement MOTOR REMOVAL 1. Remove wiper arms and blades. 2. Remove the cowl screen. 3. Remove wiper motor assembly. Linkage Removal 4. Disconnect drive linkage from motor output crank. Using an ball joint/tie rod separator, separate the ball cap from the ball. 5. Remove motor mounting nuts and remove motor. 6. Disconnect wire connector at motor. MOTOR INSTALLATION - For installation, reverse the above procedures. Tighten the mounting screws to 10 to 12 N.m (89 to 106 in. lbs.) torque. Ensure that the motor connector seal is properly positioned. Tighten the motor mounting nuts to 25 to 30 N.m (19 to 23 ft. lbs.) torque. MOTOR ASSEMBLY REMOVAL Wiper Motor And Linkage Module 1. Remove wiper arms and blades. 2. Remove the cowl screen. 3. Remove the four wiper motor mounting screws then lift assembly to gain access to clip. 4. Disconnect harness clip from the forward mounting leg. 5. Disconnect wire connector at motor and remove assembly. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Replacement > Page 7491 MOTOR ASSEMBLY INSTALLATION - For installation, reverse the above procedures. Tighten the mounting screws to 10 to 12 N.m (89 to 106 in. lbs.) torque. Ensure that the motor connector seal is properly positioned. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Replacement > Page 7492 Wiper Motor: Service and Repair Wiper Motor Assembly Mounting Grommet Replacement REMOVAL 1. Remove wiper arms and blades. 2. Remove the cowl screen. 3. Remove wiper motor assembly. 4. Remove the four grommets. INSTALLATION For installation reverse the above procedures. Ensure proper position of grommets when installing: 1. The right inboard grommet is installed with insert flat facing down. The remaining grommets installed with insert flat facing up. 2. The left outboard grommet has a small eyelet. 3. The right inboard grommet threaded eyelet. 4. The two center grommets have a large eyelets Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove wiper arms and blades. 2. Remove the cowl screen. 3. Remove wiper motor assembly. Linkage Removal 4. Disconnect wiper arm linkage, by using an ball joint/tie rod separator, separate the right and left ball cap from the ball. 5. Disconnect drive link from the motor crank. Using an ball joint/tie rod separator and separate the ball cap from the ball. INSTALLATION - For installation, reverse the above procedures. Align link ball cap over ball and gently press fit against shoulder of cap to lock cap into position. If motor output crank nut was removed, tighten nut to 25 to 30 N.m (19 to 23 ft. lbs.). Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7499 Wiper Relay: Diagrams Power Distribution Center Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7500 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7501 Connector Pin-Outs Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7502 Connector Pin-Outs NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (V6-2.5L VIN H (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams

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