Dodge - Stratus - Workshop Manual - 1998 - 1998

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Factory Workshop Manual Make Dodge Model Stratus Engine and year L4-2.4L VIN X (1998) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Adjustments Keyless Entry Module: Adjustments The scan tool (DRB) and the transmitter must be used to program the Remote Keyless Entry Module. Refer to the scan tool (DRB) for the procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Adjustments Keyless Entry Module: Adjustments The scan tool (DRB) and the transmitter must be used to program the Remote Keyless Entry Module. Refer to the scan tool (DRB) for the procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES Fuse Locations In Power Distribution Center The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center (PDC). The PDC is located on the drivers side of the engine compartment forward of the strut tower. ABS RELAYS On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will need to be replaced. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Controller Antilock Brakes To HCU Mounting Bolts ............................................................................................................................. 2 Nm (17 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 18 Electronic Brake Control Module: Locations ICU Mounting Location Mounted on the crossmember over the steering gear on the right side. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 19 Controller Antilock Brakes Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 20 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock Brake System (ABS) amber warning lamp. The primary functions of the CAB are to: - detect wheel locking tendencies - control fluid pressure modulation to the brakes during antilock stop - monitor the system for proper operation - provide communication to the DRB while in diagnostic mode - store diagnostic information in non-volatile memory The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB for proper operation If the CAB detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp. If the antilock function is disabled, the system will revert to standard base brake system operation. CAB Inputs Include The Following: - ABS Warning Lamp - Diagnostic Communication - Four Wheel Speed Sensors - Ignition Switch - Fused B+ - Stop Lamp Switch CAB Outputs Include The Following: - ABS Warning Light Actuation - Voltage - Eight Valves - Diagnostic Communication - Body Controller Communication Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 21 Electronic Brake Control Module: Service and Repair REMOVE NOTE: To replace the Controller Antilock Brakes (CAB) on this vehicle, the Integrated Control Unit (ICU) and CAB need to be removed from the vehicle as a unit. The CAB can then be separated from the Hydraulic Control Unit (HCU). Do not attempt to replace the CAB with the ICU mounted in the vehicle. 1. Remove the ICU from the vehicle. Pump Motor To CAB Wiring Harness 2. Unplug the pump motor wiring harness from the CAB. CAB Attaching Bolts 3. Remove the 4 bolts attaching the CAB to the HCU. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 22 Remove/Install CAB 4. Remove the CAB from the HCU. INSTALL 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU. 5. Bleed the base brakes and the ABS brakes hydraulic system. 6. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module Relay > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions Radiator Cooling Fan Control Module Relay: Technical Service Bulletins Cooling System - Manual Revisions NUMBER: 26-11-97G GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L/2.4L/2.5L SFI Engine Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the radiator fan control relay test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module Relay > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions > Page 28 98 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay Power Distribution Center, Hi Speed Rad Fan Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay > Page 33 Power Distribution Center, Lo Speed Radiator Fan Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay > Page 34 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Radiator Fan Relay Power Distribution Center, Hi Speed Rad Fan Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Radiator Fan Relay > Page 37 Power Distribution Center, Lo Speed Radiator Fan Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 43 Power Distribution Center, A/C Clutch Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 44 Power Distribution Center, A/C Clutch Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair Control Module HVAC: Service and Repair HVAC Control Module The control module is located below the radio. REMOVAL 1. Place the ignition key in the OFF position before removing control module. Control Module 2. Remove trim bezel. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Page 48 6. Remove the control module retaining screws. 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 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. 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 1800 if the cable is properly adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 53 Battery Discharge Protection Relay: Description and Operation SYSTEM OPERATION 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 headlamp 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection Headlamp Relay: Testing and Inspection For test of headlamp relay use a known good relay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 63 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. See the Diagnosis and Testing for more information on the operation of the horn relay. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 64 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 65 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations ABS Fuses Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 72 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 73 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 74 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 75 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 76 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 77 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations ETACS-ECU Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 84 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 85 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 93 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 94 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 95 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 96 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 97 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 (L4-2.4L VIN X (1998)) 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 98 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 (L4-2.4L VIN X (1998)) 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 99 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 100 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 (L4-2.4L VIN X (1998)) 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 101 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 102 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 (L4-2.4L VIN X (1998)) 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 103 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 (L4-2.4L VIN X (1998)) 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 104 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 (L4-2.4L VIN X (1998)) 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 105 Body Control Module: Connector Views BCM Connector BCM Connector BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 106 BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 107 Body Control Module: Electrical Diagrams Body Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 108 CCD Bus Wiring Diagrams Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 109 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 110 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 111 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 112 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 113 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 114 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 115 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 116 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 117 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 118 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Description Body Control Module: Description and Operation Description 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, the airbag control module (ACM), the smart key immobilized system (SKIM) and the antilock brake module (CAB). 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 - 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 - Power top inhibit (JX) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Description > Page 121 Body Control Module: Description and Operation Introduction 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics 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. 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. Diagnostic Strategies VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis of the body system is done in six basic steps: Verification Of Complaint - Verification Of Any Related Symptoms - Symptom Analysis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Tests and General Diagnostics > Page 124 - Problem Isolation - Repair Of Isolated Problem - Verification Of Proper Operation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 125 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 > Page 129 Powertrain Control Module: 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 (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) 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 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) 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 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 146 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 (L4-2.4L VIN X (1998)) 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 147 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 (L4-2.4L VIN X (1998)) 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 148 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 (L4-2.4L VIN X (1998)) 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 149 Powertrain Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 150 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 153 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 (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) 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 > Service and Repair > Important Notes Powertrain Control Module: Service and Repair Important Notes IMPORTANT NOTE: If the Powertrain Control Module (PCM) has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Service and Repair > Important Notes > Page 158 Powertrain Control Module: Service and Repair Procedure 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. NOTE: Use the DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and original mileage. If this step is not done a diagnostic trouble code may be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 164 Automatic Shut Down (ASD) Relay: Description and Operation Fig 12 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 Power Distribution Center (PDC) -- located in the engine compartment. The inside top of the PDC cover has label showing relay and fuse identification. Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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 (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test > Page 167 TEST 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Locations Fuel Pump Relay: Component Locations Power Distribution Center, Fuel Pump Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Locations > Page 173 Power Distribution Center Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Locations > Page 174 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 175 Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 176 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 177 Fuel Pump Relay: Testing and Inspection Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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. TEST Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 178 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 182 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 183 Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: Description and Operation Fig 12 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 Power Distribution Center (PDC) -- located in the engine compartment. The inside top of the PDC cover has label showing relay and fuse identification. Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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 (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test > Page 187 TEST 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 192 Air Bag Control Module: Diagrams Air Bag Control Module Connector Air Bag Control Module Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 193 Air Bag Control Module: Description and Operation SYSTEM OPERATION Airbag Control Module The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The impact sensor acts as a threshold sensitive switch that completes a circuit when an impact provides sufficient deceleration. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. The ACM monitors the system to determine the system readiness. The ACM stores sufficient energy to deploy the airbags for approximately two Minutes after the battery is disconnected. The ACM contains on-board diagnostics, and illuminates the AIRBAG warning lamp in the cluster when a diagnostic trouble code occurs. The warning equipment is tested for a few Seconds every time the vehicle is started. Driver And Passenger Airbag Module WARNING: NEVER DISASSEMBLE THE DRIVER OR PASSENGER AIRBAG MODULE, THERE ARE NO SERVICEABLE PARTS WITH IN THE MODULE. Driver And Passenger Airbag The Driver Airbag Module located in the center of the steering wheel is the most visible part of the system. 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. 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 Airbag Module is mounted directly to the steering wheel. The Passenger Airbag Module is located beneath the decorative cover of the instrument panel, facing the passenger seat. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 194 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 A IMPACT SENSOR WHICH 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. For a manual transmission, remove shifter knob and boot. 3. Remove the four attaching screws floor console. 4. Remove the four floor shifter mounting nuts. Airbag Control Module 5. Remove two rear module mounting nuts and remove module. INSTALLATION CAUTION: USE SUPPLIED NUTS ONLY - For installation, reverse the above procedures. 1. Position ACM (arrow pointing forward) on center tunnel area mounting studs. 2. Attach the two rear mounting nuts and tighten to 15 to 19 N.m (125 to 160 in. lbs.) torque. 3. DO NOT CONNECT battery negative remote cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations Power Distribution Center Starter Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations > Page 200 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 201 Power Distribution Center Starter Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 202 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 88A and 30, and no continuity between terminals 88 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 85 ± 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 88 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 Starting and Charging/Starting System/Ignition Switch/Testing and Inspection/Procedures. 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 213 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 214 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 220 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 221 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 224 Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 225 Power Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 226 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 227 Fuse Block PCM Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 228 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 231 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 234 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 (L4-2.4L VIN X (1998)) 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 235 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 (L4-2.4L VIN X (1998)) 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 236 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 (L4-2.4L VIN X (1998)) 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 237 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 (L4-2.4L VIN X (1998)) 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 238 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 (L4-2.4L VIN X (1998)) 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 239 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 (L4-2.4L VIN X (1998)) 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 240 - 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 (L4-2.4L VIN X (1998)) 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 241 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 (L4-2.4L VIN X (1998)) 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 242 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 (L4-2.4L VIN X (1998)) 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 243 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 244 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 (L4-2.4L VIN X (1998)) 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 245 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 (L4-2.4L VIN X (1998)) 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 246 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 (L4-2.4L VIN X (1998)) 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 247 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 250 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 (L4-2.4L VIN X (1998)) 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 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 254 Transmission Control Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 259 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 13 for battery voltage. If voltage is OK, go to Step 2. If voltage is not OK, repair A4 circuit. b. Test the rear window defogger relay terminal for battery voltage with the key in the run position. If voltage is OK, go to Step 3. If voltage is not OK, repair A31 circuit. c. Use a known good relay. If not OK, repair circuits as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 260 Heated Glass Element Relay: Service and Repair REMOVAL AND INSTALLATION 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams Door Sensor/Switch (For Alarm): Diagrams Left Key Cylinder Switch Connector Right Key Cylinder Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 270 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Key Cylinder Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 278 Power Door Lock Switch: Diagrams Power Door Lock Switch Connector Power Door Lock Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 279 Power Door Lock Switch: Testing and Inspection Remove the switch from its mounting location. Using an ohmmeter, test door lock switch continuity. Door Lock Switch Continuity Test Refer to the above image and move the switch to the Lock and Unlock positions. If the resistance values are not obtained, replace the switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 280 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 284 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 (L4-2.4L VIN X (1998)) 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 Switch Removal 1. Remove switch from mounting position. Power Seat Switch 2. Using an ohmmeter, perform the switch continuity tests. Refer to the Switch Continuity Test table. If there is no continuity in any of the switch positions, replace switch. 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. Using a voltmeter, connect the ground lead to Pin 5 of the switch harness connector. Connect the positive lead to Pin 1. If battery voltage is seen, the ground and B+ circuit is OK. If no voltage is seen, check the circuit breaker and repair as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 288 Power Seat Switch: Service and Repair REMOVAL Switch Removal 1. Remove left cushion side shield. 2. Disconnect wiring from switch. 3. Remove the seat and recliner switch knobs. 4. Remove attaching screws and switch from bezel. INSTALLATION - For installation, reverse the above procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp circuit. This switch does not disable the ABS system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 293 Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the 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 the retaining tabs on the end of the brake fluid level sensor. Removing Fluid Level Switch From Reservoir Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 294 3. While compressing retaining tabs, grasp opposite end of brake fluid level sensor and pull it out of master cylinder fluid reservoir. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Resistance 2,160 - 2,640 ohms Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 299 Wheel Speed Sensor: Mechanical Specifications Total Indicator Run Out Allowed 0.006 in Front Rear Air Gap 0.007 - 0.072 in 0.015 - 0.059 in Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 302 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 305 Wheel Speed Sensor: Diagrams Rear Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 306 Wheel Speed Sensor: Testing and Inspection CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tonewheels 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 Tonewheel Runout in the Specification Section in this section of the service manual for the tonewheel runout specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect tonewheels for looseness on their mounting surfaces. Tonewheels 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. Refer to Wheel Speed Sensor Clearance in the Specification Section in this section of the service manual. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 REMOVE 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 309 Speed Sensor Head Attachment To Steering Knuckle 5. Remove bolt attaching speed sensor to 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. INSTALL 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 shown ay result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 310 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 as shown. 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.). 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 pin. Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pin. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 311 Wheel Speed Sensor: Service and Repair Rear REMOVE 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 312 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 from the rear brake support plate. INSTALL 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. 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 (76 inch lbs.). 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. 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. 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. 9. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sensor Tightening Torque 20 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 318 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 319 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 14 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD bus to the Body Control Module (BCM) for the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies, the ECT sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor threads into the intake manifold next to the coolant fill neck/thermostat housing Fig. 14. New sensors have sealant applied to the threads. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 17 Engine Coolant Temperature Sensor To perform a complete test of this sensor and its circuitry, refer to DRB or scan tool and appropriate Computers and Control Systems/System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from coolant temperature sensor. 2. Connect one lead of a high input impedance (digital) volt-ohmmeter to one terminal of sensor. 3. Connect the other ohmmeter lead to remaining terminal of 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 322 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Temperature Gauge Indication 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 (L4-2.4L VIN X (1998)) 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 323 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.2 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located at the rear of the cylinder head next to the camshaft position sensor Fig. 2. REMOVAL 1. With the engine cold, drain the cooling system until coolant level drops below sensor. Refer to Cooling System. 2. Disconnect ECT sensor electrical connector. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Tighten sensor to 27 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 328 Brake Switch (Cruise Control): Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch refer to Lighting and Horns/Brake Lamp/Stop Switch Replacement. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 329 Brake Switch (Cruise Control): Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations On/Off Cancel, Set/Resume Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 334 Steering Column Connectors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 335 Speed Control Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 336 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. 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. NOTE: Depressing the OFF switch or turning oft the ignition switch will erase the set speed stored in the PCM. For added safety,the speed control system is programmed to disengaged for 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 when speed is greater than 25 mph restores the vehicle to the target speed that was stored in the PCM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. While the speed control is engaged, the driver can increase the vehicle speed by depressing the RES/ACCEL switch. The new target speed is stored in the PCM when the RES/ACCEL 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 individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 337 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 346 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 352 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 355 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations 2.4L Engine Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams EVAP Temp Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 364 Evaporator Temperature Sensor / Switch: Description and Operation SYSTEM OPERATION 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 0.94 degree Celsius. (33.7 degree Fahrenheit). It is allowed to switch ON when the probe temperature reaches 2.05 degree Celsius. (35.7 degree Fahrenheit). The evaporator probe is located on the lower right side of the evaporator housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation Refrigerant Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION 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 screwed attached to a valve on the discharge line near the compressor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 368 Refrigerant Pressure Sensor / Switch: Service and Repair 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. Hoist vehicle. 2. 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. Pressure Transducer (Viewed From Beneath Vehicle) 3. 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. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Door Ajar Switch Door Ajar Switch Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 375 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 376 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 377 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 378 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 379 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 380 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 381 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 382 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 383 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 384 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 385 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 386 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 387 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 388 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 389 Door Switch: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 390 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 391 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 392 Door Ajar System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Sending Unit Resistance Chart Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Lamp Switch, Brake Lamp Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 400 Brake Lamp Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 401 Brake Light 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 402 Brake Light 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 403 Brake Light Switch: Adjustments 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. Stop Light Switch Location In Vehicle 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 404 Brake Light Switch: Service and Repair REMOVE Stop Light Switch Location In Vehicle 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Door Ajar Switch Door Ajar Switch Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 410 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 411 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 412 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 413 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 414 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 415 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 416 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 417 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 418 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 419 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 420 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 421 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 422 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 424 Door Switch: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 425 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 426 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Door Ajar System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation GENERAL INFORMATION 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. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 434 Hazard Warning Switch: Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 435 Hazard Warning Switch: Service and Repair 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 439 Headlamp Dimmer Switch: Service and Repair REMOVAL AND INSTALLATION The headlamp dimmer switch is incorporated into the turn signal switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection > Page 443 Horn Switch: Service and Repair Horn Contact Switch 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 447 Turn Signal Switch: Description and Operation GENERAL INFORMATION 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. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 448 Turn Signal Switch: Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 449 Turn Signal Switch: Service and Repair 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Left Front Of Impact Beam Below Grille, Battery Temperature Sensor, Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 455 Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 456 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 457 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 460 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 467 Camshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Camshaft Sensor Pick Up Bolts ..................................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 468 Camshaft Position Sensor: Locations Crank Shaft Position Sensor Camshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 469 Cam Shaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 470 Camshaft Position Sensor: Description and Operation Fig. 3 Camshaft Position Sensor 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. The sensor also acts as a thrust plate to control camshaft end play. Fig. 4 Target Magnet--Typical Fig. 5 Target Magnet Polarity Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 471 OPERATION The camshaft position sensor attaches to the rear of the cylinder head Fig. 4. A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity Fig. 5. The sensor input switches from high (5 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 472 Camshaft Position Sensor: Service and Repair Fig. 6 Camshaft Position Sensor Location Fig. 7 Target Magnet Removal Fig. 8 Target Magnet Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head Fig. 6. REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. 2. Remove air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove camshaft position sensor mounting screws. Remove sensor. 5. Loosen screw attaching target magnet to rear of camshaft Fig. 7. NOTE: The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 473 INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 4. Install air cleaner inlet tube and filtered air tube -- if applicable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sensor Tightening Torque 20 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 477 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 478 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 14 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD bus to the Body Control Module (BCM) for the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies, the ECT sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor threads into the intake manifold next to the coolant fill neck/thermostat housing Fig. 14. New sensors have sealant applied to the threads. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 17 Engine Coolant Temperature Sensor To perform a complete test of this sensor and its circuitry, refer to DRB or scan tool and appropriate Computers and Control Systems/System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from coolant temperature sensor. 2. Connect one lead of a high input impedance (digital) volt-ohmmeter to one terminal of sensor. 3. Connect the other ohmmeter lead to remaining terminal of 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 481 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Temperature Gauge Indication 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 (L4-2.4L VIN X (1998)) 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 482 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.2 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located at the rear of the cylinder head next to the camshaft position sensor Fig. 2. REMOVAL 1. With the engine cold, drain the cooling system until coolant level drops below sensor. Refer to Cooling System. 2. Disconnect ECT sensor electrical connector. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Tighten sensor to 27 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 487 Crankshaft Position Sensor: Mechanical Specifications Sensor Screw Tightening Torque 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 488 Crankshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 489 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 490 Crankshaft Position Sensor: Description and Operation Fig 8 Timing Reference Notches Fig. 6 Timing Reference Notches Fig 9 Crankshaft Position Sensor OPERATION The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The second crankshaft counter-weight has machined into it two sets of four timing reference notches including a 60° signature notch Fig. 6. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 491 If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. The faster the engine is operating, the smaller the pulse-width on the oscilloscope. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69° Before Top Dead Center (BTDC). The second notch represents 49° BTDC. The third notch represents 29°. The last notch in each set represents 9° Before Top Dead Center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Fig. 8 Crankshaft Position Sensor The crankshaft position sensor attaches to the cowl side of the engine block. It is located between the main bearing cap/bed plate assembly and block behind the power steering pump Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 492 Crankshaft Position Sensor: Service and Repair Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter Fig. 9. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 499 Intake Manifold, Map Sensor, Throttle Body, Intake Air Tempt. Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 500 Intake Air Tempt. Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 501 Intake Air Temperature Sensor: Description and Operation Fig. 10 Intake Air Temperature Sensor And MAP Sensor The Intake Air Temperature (IAT) sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. The IAT sensor threads into the intake manifold. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 8 MAP Sensor And Intake Air Temperature Sensor To perform a complete test of this sensor and its circuitry; refer to DRB or Scan Tool and appropriate Computers and Control Systems/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. 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 504 Intake Air Temperature Sensor: Service and Repair Fig. 20 Intake Air Temperature Sensor And MAP Sensor The intake air temperature sensor threads into the intake manifold plenum Fig. 20. REMOVAL 1. Remove air inlet resonator. 2. Reaching through intake manifold from throttle body end, disconnect sensor connector. 3. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Attach electrical connector to sensor. 3. Install air inlet resonator. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor Torque 90 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 508 Knock Sensor: Locations Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 15 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 15. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increase, the knock sensor output voltage also increases. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 511 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code NAME OF CODE: Knock Sensor Circuit WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The knock sensor circuit voltage (cavity 27) falls below a minimum value at idle or deceleration. The minimum value is from a look-up table internal to the Powertrain Control Module (PCM) and is based on engine RPM. The trouble code also sets if the sensor output is above 5.0 volts. THEORY OF OPERATION: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezo-electric discs, producing an electrical signal. The signal is used by PCM cavity 27 to adjust ignition timing to eliminate the knock condition. POSSIBLE CAUSES: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 512 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. RMS voltage starts at about 20mVac -- at about 700 rpm - and increases to approximately 600 mVac -- at 5,000 rpm. If the output falls outside of this range a DTC will be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 513 Knock Sensor: Service and Repair Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. REMOVAL 1. Disconnect electrical connector from knock sensor Fig. 12. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 518 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP sensor torque .............................................................................................................................. .......................................................... 2 Nm (20 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 519 Manifold Pressure/Vacuum Sensor: Locations MAP Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 520 Map Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 521 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 10 Intake Air Temperature Sensor And MAP Sensor OPERATION The Powertrain Control Module (PCM) supplies 5 volts to the Manifold Absolute Pressure (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. During cranking, before the engine starts running, 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 MAP sensor mounts to the intake manifold Fig. 10. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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 36 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 43. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 524 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 14 Temperature Sensor And MAP Sensor The MAP sensor attaches to the intake manifold plenum Fig. 14. REMOVAL 1. Disconnect the electrical connector from the 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 2 Nm (20 in. lbs) torque. 3. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Sensor Torque 20 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 530 Rear Bank Upstream Oxygen Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 531 Down Stream Heated Oxygen Sensor, Catalytic Convertor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > 1/1 Upstream Oxygen Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > 1/1 > Page 534 Downstream Oxygen Sensor Connector (Harness Side) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 535 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 536 Oxygen Sensor: Description and Operation Fig 11 Upstream Heated Oxygen Sensor 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 11). Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 537 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 538 Oxygen Sensor: Testing and Inspection 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: Complete testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig 90 Downstream Heated Oxygen Sensor Removal/Installation NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor. REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 90). 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 sensor electrical harness to clips along. body 3. Connect electrical connector to sensor. 4. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 541 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig 88 Upstream Heated Oxygen Sensor Removal/Installation 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. 88). 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 542 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 547 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 (L4-2.4L VIN X (1998)) 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 548 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 549 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 550 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 555 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 556 Fig. 35 Throttle Position Sensor And Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 557 Throttle Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 558 Throttle Position Sensor: Description and Operation Fig. 22 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 mounts to the side of the throttle body Fig. 22. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Testing 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 561 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 562 Throttle Position Sensor: Service and Repair Fig. 35 Throttle Position Sensor And Idle Air Control Motor THROTTLE POSITION SENSOR (TPS) SERVICE The throttle position sensor attaches to the side of the throttle body Fig. 35. 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 throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 36 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 36. - 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. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 571 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 (L4-2.4L VIN X (1998)) 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 572 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 (L4-2.4L VIN X (1998)) 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 573 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 579 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 (L4-2.4L VIN X (1998)) 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 580 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 585 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 (L4-2.4L VIN X (1998)) 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 586 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 (L4-2.4L VIN X (1998)) 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 587 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 593 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 (L4-2.4L VIN X (1998)) 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 594 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 (L4-2.4L VIN X (1998)) 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 595 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 598 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 599 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 600 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 (L4-2.4L VIN X (1998)) 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 601 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 (L4-2.4L VIN X (1998)) 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 602 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions Vehicle Speed Sensor: Technical Service Bulletins Cooling System - Manual Revisions NUMBER: 26-11-97G GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L/2.4L/2.5L SFI Engine Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the radiator fan control relay test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions > Page 607 98 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Manual Transmission Only Vehicle Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Manual Transmission Only > Page 610 Vehicle Speed Sensor, Transaxle Extension Housing Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 613 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 614 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 615 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 616 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 617 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 618 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 619 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 620 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 621 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 622 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 (L4-2.4L VIN X (1998)) 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 623 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 (L4-2.4L VIN X (1998)) 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 624 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 625 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 (L4-2.4L VIN X (1998)) 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 626 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 627 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 (L4-2.4L VIN X (1998)) 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 628 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 (L4-2.4L VIN X (1998)) 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 629 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 (L4-2.4L VIN X (1998)) 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 630 Vehicle Speed Sensor: Connector Views Vehicle Speed Sensor Vehicle Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 631 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. Vehicle Speed And Distance The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. Vehicles with a 3 speed automatic or manual transmission have a vehicle speed sensor (VSS) mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Management/Computer and Control System for diagnosis and testing of this component 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 632 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 638 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 639 Fig. 35 Throttle Position Sensor And Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 640 Throttle Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 641 Throttle Position Sensor: Description and Operation Fig. 22 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 mounts to the side of the throttle body Fig. 22. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Testing 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 644 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 645 Throttle Position Sensor: Service and Repair Fig. 35 Throttle Position Sensor And Idle Air Control Motor THROTTLE POSITION SENSOR (TPS) SERVICE The throttle position sensor attaches to the side of the throttle body Fig. 35. 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 throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 36 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 36. - 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 653 Camshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Camshaft Sensor Pick Up Bolts ..................................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 654 Camshaft Position Sensor: Locations Crank Shaft Position Sensor Camshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 655 Cam Shaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 656 Camshaft Position Sensor: Description and Operation Fig. 3 Camshaft Position Sensor 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. The sensor also acts as a thrust plate to control camshaft end play. Fig. 4 Target Magnet--Typical Fig. 5 Target Magnet Polarity Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 657 OPERATION The camshaft position sensor attaches to the rear of the cylinder head Fig. 4. A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity Fig. 5. The sensor input switches from high (5 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 658 Camshaft Position Sensor: Service and Repair Fig. 6 Camshaft Position Sensor Location Fig. 7 Target Magnet Removal Fig. 8 Target Magnet Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head Fig. 6. REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. 2. Remove air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove camshaft position sensor mounting screws. Remove sensor. 5. Loosen screw attaching target magnet to rear of camshaft Fig. 7. NOTE: The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 659 INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 4. Install air cleaner inlet tube and filtered air tube -- if applicable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 664 Crankshaft Position Sensor: Mechanical Specifications Sensor Screw Tightening Torque 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 665 Crankshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 666 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 667 Crankshaft Position Sensor: Description and Operation Fig 8 Timing Reference Notches Fig. 6 Timing Reference Notches Fig 9 Crankshaft Position Sensor OPERATION The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The second crankshaft counter-weight has machined into it two sets of four timing reference notches including a 60° signature notch Fig. 6. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 668 If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. The faster the engine is operating, the smaller the pulse-width on the oscilloscope. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69° Before Top Dead Center (BTDC). The second notch represents 49° BTDC. The third notch represents 29°. The last notch in each set represents 9° Before Top Dead Center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Fig. 8 Crankshaft Position Sensor The crankshaft position sensor attaches to the cowl side of the engine block. It is located between the main bearing cap/bed plate assembly and block behind the power steering pump Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 669 Crankshaft Position Sensor: Service and Repair Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter Fig. 9. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 679 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 680 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 (L4-2.4L VIN X (1998)) 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 681 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 (L4-2.4L VIN X (1998)) 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 682 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 (L4-2.4L VIN X (1998)) 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 683 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 (L4-2.4L VIN X (1998)) 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 684 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 (L4-2.4L VIN X (1998)) 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 685 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 (L4-2.4L VIN X (1998)) 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 686 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 (L4-2.4L VIN X (1998)) 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 687 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 (L4-2.4L VIN X (1998)) 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 688 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 (L4-2.4L VIN X (1998)) 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 689 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 (L4-2.4L VIN X (1998)) 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 690 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 696 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 697 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 (L4-2.4L VIN X (1998)) 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 698 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 (L4-2.4L VIN X (1998)) 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 699 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 (L4-2.4L VIN X (1998)) 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 700 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 (L4-2.4L VIN X (1998)) 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 701 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 (L4-2.4L VIN X (1998)) 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 702 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 (L4-2.4L VIN X (1998)) 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 703 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 (L4-2.4L VIN X (1998)) 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 704 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 (L4-2.4L VIN X (1998)) 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 705 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 (L4-2.4L VIN X (1998)) 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 706 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 (L4-2.4L VIN X (1998)) 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 707 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 708 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 (L4-2.4L VIN X (1998)) 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 709 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 (L4-2.4L VIN X (1998)) 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 710 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor Torque 90 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 714 Knock Sensor: Locations Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 15 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 15. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increase, the knock sensor output voltage also increases. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 717 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code NAME OF CODE: Knock Sensor Circuit WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The knock sensor circuit voltage (cavity 27) falls below a minimum value at idle or deceleration. The minimum value is from a look-up table internal to the Powertrain Control Module (PCM) and is based on engine RPM. The trouble code also sets if the sensor output is above 5.0 volts. THEORY OF OPERATION: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezo-electric discs, producing an electrical signal. The signal is used by PCM cavity 27 to adjust ignition timing to eliminate the knock condition. POSSIBLE CAUSES: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 718 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. RMS voltage starts at about 20mVac -- at about 700 rpm - and increases to approximately 600 mVac -- at 5,000 rpm. If the output falls outside of this range a DTC will be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 719 Knock Sensor: Service and Repair Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. REMOVAL 1. Disconnect electrical connector from knock sensor Fig. 12. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 725 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 (L4-2.4L VIN X (1998)) 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 726 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 727 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 728 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 729 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 730 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 (L4-2.4L VIN X (1998)) 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 731 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 (L4-2.4L VIN X (1998)) 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 732 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 733 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 734 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 735 PARTS REQUIRED: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 736 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 (L4-2.4L VIN X (1998)) 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 737 POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Left Front Of Impact Beam Below Grille, Battery Temperature Sensor, Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 745 Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 746 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 747 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 750 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 760 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 761 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 (L4-2.4L VIN X (1998)) 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 762 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 (L4-2.4L VIN X (1998)) 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 763 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 (L4-2.4L VIN X (1998)) 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 764 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 (L4-2.4L VIN X (1998)) 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 765 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 (L4-2.4L VIN X (1998)) 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 766 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 (L4-2.4L VIN X (1998)) 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 767 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 (L4-2.4L VIN X (1998)) 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 768 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 (L4-2.4L VIN X (1998)) 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 769 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 (L4-2.4L VIN X (1998)) 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 770 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 (L4-2.4L VIN X (1998)) 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 771 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 777 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 778 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 (L4-2.4L VIN X (1998)) 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 779 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 (L4-2.4L VIN X (1998)) 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 780 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 (L4-2.4L VIN X (1998)) 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 781 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 (L4-2.4L VIN X (1998)) 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 782 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 (L4-2.4L VIN X (1998)) 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 783 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 (L4-2.4L VIN X (1998)) 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 784 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 (L4-2.4L VIN X (1998)) 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 785 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 (L4-2.4L VIN X (1998)) 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 786 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 (L4-2.4L VIN X (1998)) 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 787 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 (L4-2.4L VIN X (1998)) 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 788 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 789 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 790 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 791 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 798 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 799 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 800 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 801 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch Autostick Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch > Page 808 Transmission Range Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 817 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 (L4-2.4L VIN X (1998)) 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 818 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 (L4-2.4L VIN X (1998)) 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 819 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 825 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 (L4-2.4L VIN X (1998)) 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 826 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 831 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 (L4-2.4L VIN X (1998)) 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 832 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 (L4-2.4L VIN X (1998)) 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 833 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 839 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 (L4-2.4L VIN X (1998)) 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 840 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 (L4-2.4L VIN X (1998)) 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 841 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 844 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 845 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 846 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 (L4-2.4L VIN X (1998)) 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 847 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 (L4-2.4L VIN X (1998)) 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 848 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 857 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 862 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 (L4-2.4L VIN X (1998)) 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 863 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 (L4-2.4L VIN X (1998)) 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 864 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 870 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 875 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 (L4-2.4L VIN X (1998)) 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 876 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 (L4-2.4L VIN X (1998)) 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 877 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 (L4-2.4L VIN X (1998)) 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 878 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 879 Input / Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 882 Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 883 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 Continuity Test Passenger Window Switch Continuity Test For switch testing, remove the switch from its mounting, refer to Switch Removal. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 891 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 Power Window Switch Passenger Switch 1. Remove passenger door trim panel. 2. Disconnect switch wire connector. 3. Using a trim stick (special tool #C-4755), gently pry out switch from bezel being careful not to damage bezel. INSTALLATION Master Switch and Passenger Switch For installation, reverse the the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 896 Windshield Washer Switch: Description and Operation GENERAL INFORMATION Multi-Function Switch WARNING: VEHICLES ARE EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR STEERING WHEEL OR COLUMN SERVICE PROCEDURES. Multi-Function 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. To use the washers pull lever toward the driver. The mist is a single wipe operation by pushing lever down and releasing the lever. Intermittent wiper operation is controlled by the Body Control Module (BCM). The lever has a selection of delay intervals and by turning lever the wiper will cycle every half Second to 36 Seconds depending ON the vehicle's speed. The wiper has two cycle two speeds. The windshield wipers will only operate when the ignition switch is in the ACCESSORY or IGNITION position. Fuse 15, located in the Junction Block, fuses 8 and 14 in the Power Distribution Center block, protects the wiper/washer system circuitry The wiper motor also has an internal non-serviceable circuit breaker to provide protection against motor stall conditions The wiper and washer motors have magnetic fields created by internal permanent magnet. Electric power applied to the motor armature, located in the magnetic field, causes the motor to turn. The wiper system internal operation uses the low speed motor circuit in combination with intermittent wipe relay. The washer pump motor has one internal circuit and therefore operates at one speed. The wiper and washer system switch located on the steering column selects the mode of operation of the motors. The switch provides input to the BCM, which in turn operates the two relays. The intermittent wipe relay turns the wiper ON and OFF. The other changes the HIGH/LOW speeds. The switch also provides power to the washer pump motor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 897 The intermittent wiper system, in addition to low and high speed, has a delay mode. The delay mode has a range of 1/2 to 18 Seconds when the vehicle speed is over 10 mph The wiper delay times will automatically double to a range of 1 to 36 Seconds when the vehicle speed is less than 10 mph The delay is controlled by a variable resistor in the wiper switch and BCM. The wiper motor and washer motor are designed to reduce radio frequency interference and provide electro-magnetic compatibility (RFI/EMC) in the vehicle environment. This is done with suppression circuits designed into the motors. The wiper system completes the wipe cycle when the switch is turned OFF. The blades park in the lowest portion of the wipe pattern. When using a scan tool (DRB) refer to the Body Diagnostic for the procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 898 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering ad Suspension/steering column/steering column cover removal procedures below. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 902 Wiper Switch: Description and Operation GENERAL INFORMATION Multi-Function Switch WARNING: VEHICLES ARE EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR STEERING WHEEL OR COLUMN SERVICE PROCEDURES. Multi-Function 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. To use the washers pull lever toward the driver. The mist is a single wipe operation by pushing lever down and releasing the lever. Intermittent wiper operation is controlled by the Body Control Module (BCM). The lever has a selection of delay intervals and by turning lever the wiper will cycle every half Second to 36 Seconds depending ON the vehicle's speed. The wiper has two cycle two speeds. The windshield wipers will only operate when the ignition switch is in the ACCESSORY or IGNITION position. Fuse 15, located in the Junction Block, fuses 8 and 14 in the Power Distribution Center block, protects the wiper/washer system circuitry The wiper motor also has an internal non-serviceable circuit breaker to provide protection against motor stall conditions The wiper and washer motors have magnetic fields created by internal permanent magnet. Electric power applied to the motor armature, located in the magnetic field, causes the motor to turn. The wiper system internal operation uses the low speed motor circuit in combination with intermittent wipe relay. The washer pump motor has one internal circuit and therefore operates at one speed. The wiper and washer system switch located on the steering column selects the mode of operation of the motors. The switch provides input to the BCM, which in turn operates the two relays. The intermittent wipe relay turns the wiper ON and OFF. The other changes the HIGH/LOW speeds. The switch also provides power to the washer pump motor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 903 The intermittent wiper system, in addition to low and high speed, has a delay mode. The delay mode has a range of 1/2 to 18 Seconds when the vehicle speed is over 10 mph The wiper delay times will automatically double to a range of 1 to 36 Seconds when the vehicle speed is less than 10 mph The delay is controlled by a variable resistor in the wiper switch and BCM. The wiper motor and washer motor are designed to reduce radio frequency interference and provide electro-magnetic compatibility (RFI/EMC) in the vehicle environment. This is done with suppression circuits designed into the motors. The wiper system completes the wipe cycle when the switch is turned OFF. The blades park in the lowest portion of the wipe pattern. When using a scan tool (DRB) refer to the Body Diagnostic for the procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 904 Wiper Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering ad Suspension/steering column/steering column cover removal procedures below. 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 (L4-2.4L VIN X (1998)) 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 +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 ......................................................................................................... .................................................................................... + or -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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > General Information > Page 911 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 912 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 913 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 914 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fig. 1 Fuel Pressure Test Port--Typical Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 ................................................................................ .............................................................................................. 550 - 1,300 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 600 - 1,300 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 923 Idle Speed: Testing and Inspection Fig. 34 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. 34. Fig. 36 Orifice 6457 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. 36. 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 ............................................................................................................................. ........................................... 550 - 1,300 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 600 - 1,300 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. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 924 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 933 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cable Routing and Firing Order Firing Order Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable Resistance Cable #1 & #4 3,500 - 4,500 ohms Cable #2 & #3 2,950 - 4,100 ohms Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 944 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and 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. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 947 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 the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - 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, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE CABLE RESISTANCE #1 & #4 3,500 to 4,900 ohms #2 & #3 2,950 to 4,100 ohms 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 40,000 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 950 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Resistance cables are identified by the words Electronic Suppression. SPARK PLUG CABLE SERVICE The cables insulate the spark plugs and covers the top of the spark plug tube Fig. 3. To remove the cables, lightly grasp the top of the cable. Rotate the insulator 90° and pull straight up. To replace the cables, disconnect the cable from the ignition coil. Ensure the #1 and #4 cables run under the #2 and #3 ignition coil towers. Keep #4 cable away from the oil fill cap. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................... 1.21-1.34 mm (0.048-0.53 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 954 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................... RC12YC5 Thread size ..................................................... ................................................................................................................................................. (14mm) 3/4 in. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 955 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 958 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 959 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 960 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 961 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 962 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 963 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 964 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 ^ 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 0.033 - 0.038 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 965 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 966 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap 0.048 to 0.053 in Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 967 Spark Plug: Service and Repair SPARK PLUG SERVICE Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 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. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: Special care should be used when installing spark plugs in the cylinder head spark plug wells. Re sure the plugs do not drop into the wells, damage to the electrodes can occur. 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SEE Testing and Inspection/Spark Plug Condition. Fig. 4 Setting Spark Plug Electrode Gap SPARK PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground electrode Fig. 4. SPARK PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. CAUTION: Over tightening can cause distortion and change spark plug gap. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. SPARK PLUG TUBES Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 968 The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. For engine information, SEE Engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure 170-225 psi Max. Variation Between Cylinders 25% Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 972 Compression Check: Testing and Inspection 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 adapter 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this engine has hydraulic lifters or adjusters which do not require nor have provisions for adjustment. See "Rocker Arm: Service and Repair" for further information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Specifications Timing Belt: Specifications On CA vehicles except 1997-2001 Sebring Convertible & 1998-2001 Cirrus & Stratus, replacement at 60,000 mile intervals is recommended but not required. On 1997-98 Sebring Convertible & 1998 Cirrus & Stratus models, replace at 105,000 mile intervals. On 1999-2001 Cirrus, Sebring Convertible & Stratus CA vehicles, replace every 105,000 miles. On 1999-2001 Cirrus, Sebring Convertible & Stratus non-CA vehicles, replace every 100,000 miles in normal service or every 99,000 miles in severe service. On 1996 Caravan, Town & Country & Voyager models, replace at 120,000 mile intervals. On 1997-98 Caravan & Voyager models, manufacturer does not recommend a specific maintenance interval. On 1999-2001 Caravan & Voyager models, replace every 90,000 miles. On 2000-01 Cirrus & Stratus non-CA vehicles, replace every 105,000 miles or 80 months in normal service, or every 99,000 miles in severe service. On 2000-01 Cirrus & Stratus CA vehicles, replace every 105,000 miles or 84 months. On all other models, replace at 100,000 mile intervals (if not previously replaced). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation Timing Belt: Service and Repair Timing Belt Removal and Installation 1. Raise vehicle on hoist. Remove right front wheel. 2. Remove right inner splash shield. 3. Remove accessory drive belts. 4. Remove crankshaft damper bolt, and remove damper. See: Engine, Cooling and Exhaust/Engine/Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley 5. Remove lower timing belt cover fasteners and remove cover. 6. Lower vehicle and remove upper timing belt cover fasteners and remove cover. 7. Remove right engine mount and support bracket. CAUTION: When aligning crankshaft and camshaft timing marks always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt. 8. Before the removal of the timing belt, rotate crankshaft until the TDC mark on the oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 981 NOTE: The crankshaft sprocket TDC mark is located on the trailing edge of the sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause the camshaft timing marks to be misaligned. 9. Install 6 mm Allen wrench into belt tensioner. Before rotating the tensioner insert the long end of a 1/8" or 3 mm Allen wrench into the pin hole on the front of the tensioner. While rotating the tensioner counterclockwise push in lightly on the 1/8" or 3 mm Allen wrench, until it slides into the locking hole. 10. Remove timing belt. CAUTION: If timing belt was damaged due to incorrect tracking (alignment), the belt tensioner assembly must be replaced. INSTALLATION 1. Set crankshaft sprocket to Top Dead Center (TDC) by aligning the sprocket with the arrow on the oil pump housing. 2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket. CAUTION: Ensure that the arrows on both camshaft sprockets are facing up. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 982 3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner. 4. Move the exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. NOTE: A new tensioner is held in the wound position by a pull pin. 5. Remove the pull pin or Allen wrench from the belt tensioner. 6. Rotate crankshaft 2 revolutions and check the alignment of the timing marks. 7. Install right engine mount and support bracket. 8. Install upper timing belt cover bolts 4.5 Nm (40 inch lbs.). 9. Install the lower timing belt cover bolts 4.5 Nm (40 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 983 10. Install crankshaft damper. See: Engine, Cooling and Exhaust/Engine/Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair 11. Install accessory drive belts. 12. Install right inner splash shield. 13. Install right front wheel. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 984 Timing Belt: Service and Repair Updated Mechanical Tensioner Installation Information INSTALLATION - TIMING BELT 1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. Fig. 102 Camshaft Sprocket Alignment 2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket. CAUTION: Ensure that the arrows on both camshaft sprockets are facing up. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 985 Fig. 103 Timing Belt Installation - Typical 3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner. 4. Move the exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 986 Fig. 104 Timing Belt Tension Adjustment 5. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley Rotate the top plate COUNTERCLOCKWISE . The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the allen wrench to prevent the top plate from moving, torque the tensioner lock nut to 25 Nm (220 in. lbs.). Setting notch and spring tang should remain aligned after lock nut is torqued. 6. Remove allen wrench and torque wrench. NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 987 Fig. 105 Crankshaft And Camshaft Timing 7. Once the timing belt has been installed and tensioner adjusted, rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position. Fig. 106 Timing Belt Tension Verification 8. Check if the spring tang is within the tolerance window. If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 5 through 7. 9. Continue with normal installation process. See: Timing Belt Removal and Installation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions Drive Belt: Technical Service Bulletins Engine/Electrical - Belt Tension/Connector Revisions NUMBER: 26-04-98 GROUP: Miscellaneous DATE: April, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1998 Cirrus, Stratus, Breeze Service Manual - Publication Number 81-270-8121 DESCRIPTION OF CHANGES Adds a note referencing belt tension adjustment Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions > Page 992 7-27 Revises the C121 connector pin outs Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions > Page 993 8W-80-11 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions > Page 994 Drive Belt: Technical Service Bulletins Engine - Drive Belt Tension Revisions NUMBER: 26-02-98 GROUP: Miscellaneous DATE: February, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1998 Cirrus/Stratus/Breeze Service Manual - Publication Number 81-270-8121 DESCRIPTION OF CHANGES Revised belt tension specifications Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions > Page 995 7-29 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 996 Drive Belt: Description and Operation Drive Belts - All Engines The engines are equipped with 2 accessory drive belts. One belt drives the power steering pump, the other drives the generator and air conditioning. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 997 Drive Belt: Testing and Inspection Accessory Drive Belt Diagnosis Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 998 Drive Belt: Adjustments For conventional belts and Poly-V belts, use belt tensioning Special Tool Kit C-4162 to obtain proper belt tension. Belt Tension Gauge Method Adjust the belt tension for a New or Used belt as prescribed. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation Drive Belt: Service and Repair Removal and Installation The content of this article reflects changes called for in TSB 26-04-98. AIR CONDITIONING COMPRESSOR AND GENERATOR BELT Accessory Drive Belt System - All Engines Accessory Drive Belt System - All Engines 1. Loosen T-Bolt locking nut A and pivot bolt B to remove and install Poly V belt and/or adjust belt tension. 2. Tighten adjusting bolt to adjust belt tension to specification. Air Conditioning Compressor And Generator Belt Adjustment 3. Tighten T-Bolt locking nut A and pivot bolt B to 54 Nm (40 ft. lbs.). POWER STEERING PUMP BELT 1. From the top of the vehicle loosen pivot bolt C. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1001 Power Steering Belt Adjustment 2. From under the vehicle loosen locking bolts D and E. 3. Install the belt. Adjust belt tension with 1/2 inch breaker bar installed in adjusting bracket. NOTE: For accessory drive belt specifications, See: Adjustments 4. Tighten locking bolt D to 54 Nm (40 ft. lbs.). 5. Tighten locking bolt E and the pivot bolt C to 54 Nm (40 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1002 Drive Belt: Service and Repair Cleaning and Inspection Belt replacement under any or all of the following conditions is required, excessive wear, frayed cords or severe glazing. Drive Belt Wear Pattern Poly-V-Belt system may develop minor cracks across the ribbed side. These minor cracks are considered normal and acceptable. Cracks parallel are not. NOTE: Do not use any type of belt dressing or restorer on Poly-V-Belts. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 1012 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1017 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Filter ..................................................................................................................................................... .................................................... 20 Nm (15 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1021 Oil Filter: Service and Repair CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Turn counterclockwise to remove. 2. To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until the gasket contacts base. Tighten to 21 Nm (15 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Description and Operation Refrigerant Filter: Description and 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 drier is used to remove any traces of moisture from the refrigerant system. The filter is used to separate any foreign particles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Description and Operation > Page 1025 Refrigerant Filter: Service and Repair 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. Filter/Drier Location 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. Liquid Line From Condenser 2. Remove liquid line at filter/drier from condenser. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Description and Operation > Page 1026 Liquid Line From Expansion Valve 3. Remove liquid line at filter/drier from expansion valve. 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. INSTALLATION 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. - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation The inlet tube connects the water pump to the radiator and heater core. This tube is sealed by an O-ring and held in place by fasteners to the block. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Description and Operation > Page 1031 Coolant Line/Hose: Service and Repair REMOVAL 1. Drain cooling system. 2. Remove upper radiator hose to access the hose connections at the inlet tube. Water Pump Inlet Tube Hose Connections 3. Remove lower radiator hose and heater hose from the inlet tube. 4. Remove the 2 fasteners from that hold the inlet tube to the block. Water Pump Inlet Tube - Service 5. Rotate inlet tube while removing from the engine block. INSTALLATION 1. Inspect the O-ring for damage before installing the tube into the cylinder block. 2. Lube O-ring with coolant and install into the cylinder block opening. 3. Install 2 fasteners and tighten to 12 Nm (105 inch lbs.). 4. Connect lower radiator hose and heater hose to inlet tube. 5. Install upper radiator hose. 6. Fill cooling system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair The heater hoses attach at the engine compartment cowl onto the heater core inlet/outlet and on the left side of the engine. The heater hoses are serviced separately of each other. The hoses can not be serviced with bulk roll heater hose. If it is necessary to replace a hose, use hose of the exact diameter and size and shape. The hoses are attached using spring tension clamps. REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Heater Hose Connection At Engine Heater Hose Connection At Heater Core 2. Using spring tension clamp pliers, remove clamps at each end of hose to be removed. 3. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation SYSTEM OPERATION 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 aluminum 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 NC 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Disconnect A/C pressure transducer wire harness. Quick Connect Clip Special Tool For Line At Condenser 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1040 Line At Compressor 4. Disconnect line at A/C compressor. Remove discharge line. INSTALLATION - For installation, reverse the above procedures. Tighten bolts to 22 N.m (200 in. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1041 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement TO EXPANSION VALVE REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. Liquid Line Clip At Expansion Valve 2. Remove A/C quick connect clip at expansion valve. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1042 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. TO CONDENSER REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. Clip Removal 2. Remove A/C quick connect clip at condenser. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1043 Quick Coupler Using Special Tool 7240 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. CAUTION: Cap all lines that are not being replaced and cap the condenser inlet. Liquid Line At Receiver/Drier 4. Disconnect liquid line from the receiver/drier. 5. Remove the liquid line from the vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1044 INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1045 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. Suction Line Routing Clip 2. Remove suction line clip at right strut tower. Quick Connect Clip 3. Remove quick conned. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1046 Suction Line At Compressor 4. Disconnect line at compressor end. 5. Remove suction line from vehicle. INSTALLATION - For installation, reverse the above procedures. Tighten bolts to 22 N.m (200 in. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Tube Nuts ............................................................................................................................................ ................................................ 31 Nm (275 inch lbs.) Banjo Fitting Flow Bolt ..................................... ....................................................................................................................................... 47 Nm (33 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 (L4-2.4L VIN X (1998)) 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 Fig. 7 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. 2. Remove the tie-strap holding the power steering fluid supply hose to the power steering pressure hose. 3. Remove hose clamp, attaching power steering fluid supply hose to power steering fluid reservoir. Then remove power steering fluid supply hose from power steering fluid reservoir. 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. 5. Remove power steering fluid supply hose from engine. INSTALL 1. Install power steering fluid supply hose back on engine making sure it is correctly routed. 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. 2. Install power steering fluid supply hose on power steering fluid reservoir fitting. Install hose clamp on power steering fluid supply hose at power steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. 3. Install power steering fluid supply hose on power steering pump fitting. 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. CAUTION: The tie strap must be installed on the power steering pressure hose and supply hose to ensure proper routing of the hoses. 4. Install the tie-strap holding the power steering fluid supply hose to the power steering pressure hose. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 5. Fill power steering fluid reservoir. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1052 14. After hose is installed, check for leaks at all hose connections. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1053 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1054 4. Remove power steering pressure hose routing bracket from the power steering return hose bracket on rear of engine. Then remove the nut attaching the power steering pressure hose routing bracket to stud on side of cylinder head. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1055 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1056 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1057 6. Remove power steering pressure hose routing bracket from the power steering return hose routing bracket on rear of engine. Then remove the bolt attaching the power steering pressure hose routing bracket to the cylinder head. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1058 7. Install power steering return hose routing bracket on rear of cylinder head and securely tighten bolt. Then install the power steering pressure hose routing bracket on the return hose routing bracket and securely tighten attaching bolt. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1059 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. Hose Clamps At Power Steering Fluid Cooler 6. Remove the hose clamps from the power steering fluid hoses. Drain power steering fluid from the hoses and the power steering fluid cooler. Power Steering Cooler Line Attachment Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1060 7. Remove the bracket attaching the power steering fluid cooler lines to the left front frame rail. 8. Lower the front suspension crossmember. 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. Power Steering Cooler Line Attachment Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1061 2. Install the cooler lines in the routing clip on the left frame rail. 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. Torquing Power Steering Fluid Hose Tube Nuts 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.). Hose Clamps At Power Steering Fluid Cooler Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1062 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. 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 (L4-2.4L VIN X (1998)) 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 counterclockwise 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. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clam. Always wear safety glasses when servicing constant tension clamps. CAUTION: 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. Hose Clamp Tool The hose clamps are removed by using Special Tool 6094 or equivalent constant tension clamp pliers to compress hose clamp. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. Spring type hose clamps are used in all applications. If replacement is necessary replace with the original Mopers equipment spring type clamp. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1070 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact-rinse eyes thoroughly with water. * Skin Contact-wash skin with soap and water. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1071 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1072 Brake Fluid: Service and Repair BRAKE FLUID LEVEL CHECK Check master cylinder reservoir brake fluid level a minimum of twice a year. Master Cylinder Fluid Level Master cylinder reservoirs are marked with the words FULL AND MIN indicating proper range of the 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ............................................................ 8.5 L (9.0 qts) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1077 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information The cooling system is designed around the coolant. The coolant must accept heat from engine block metal and in the cylinder head area near the exhaust valves. Then coolant carries this heat to the radiator where the tube/fin assemblies of these components can give off the heat to the air. Mopar Antifreeze or the equivalent is recommended for optimum cooling performance and corrosion protection when mixed to a freeze point of -37° C (-35° F). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information > Page 1080 Coolant: Description and Operation Coolant Performance 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 the equivalent is recommended for optimum engine cooling and protection against corrosion when mixed 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 suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1081 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1086 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1087 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1088 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1089 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1090 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Service Fill Capacity ............................................................................................................................ ............................................................. 3.8L (4.0 Qt) Dry fill with empty torque converter .................. ............................................................................................................................................... 8.6L (9.1 Qt) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1093 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1096 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1097 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .......................................................... 2.1L (4.4 Pints) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1102 Fluid - M/T: Fluid Type Specifications Transmission Fluid MOPAR type M.S. 9417 Manual Transaxle Fluid Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.7L (5.0 Qt) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1110 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1111 Engine Oil: Description and Operation 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. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPAR provides engine oils that conforms to this service grade. Temperature/Engine Oil Viscosity SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. 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. Engine Oil Container Standard Notations 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1112 Engine Oil: Testing and Inspection The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. Oil Level Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Add only when the level is at or below the ADD mark. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1113 Engine Oil: Service and Repair CHANGING ENGINE OIL Change engine oil at mileage and time intervals. 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. 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. 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. ENGINE OIL FILTER CHANGE Filter Specification All engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar or equivalent oil filter be used. 0il Filter Removal Refer to Removal and Installation procedure. Used Engine 0il Disposal Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1122 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1128 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1129 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1130 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1135 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1141 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1147 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1148 Power Steering Fluid: Specifications The recommended lubricant is Mopar Power Steering Fluid. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1149 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Capacity ................................................................................................................................... ........................................ 0.74 kg (26 oz. or 1.63 lbs) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1154 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1155 Refrigerant: Description and Operation This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear 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 in a R-134a system could cause compressor failure, refrigerant oil sludging or poor performance. Never add R-12 to a system designed to use R.134a. System failure will occur. A/C Service Ports Both of the service ports to charge the air conditioning system are located on the hoses. New design of service ports have been used to ensure that the system is not accidentally filled with the wrong refrigerant (R-12). Refrigerant Recovery/Recycling Station Typical When servicing a system, it is required that an air conditioning charging recovery/recycling machine be used. Contact an automotive service equipment supplier for proper equipment. Refer to the operating instructions provided with the equipment for proper operation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1156 Manifold Gauge Set - Typical A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling device. Only use gauges that have not been used for R-12. The service hoses on the gauge set should have manual (turn wheel) or automatic back flow valves at the service port connector ends. This will prevent refrigerant R-134a from being released into the atmosphere. Underhood Label R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure that it is designed to be used in a R-134a system. Refer to the label under the hood for proper oil and refrigerant charge levels. Due to the different characteristics of R-134a it requires all new service procedures. 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 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-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. The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and low global warming impact. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1161 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1162 Refrigerant Oil: Service and Repair 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 A/C Component Refrigerant Oil Capacities 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 table. 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 ND 8 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 (L4-2.4L VIN X (1998)) 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 hydraulic system for the base brakes must be bled anytime air enters the hydraulic system. Air can enter the hydraulic system for the base brakes due to the disconnection of brake lines, hoses or any other hydraulically operated component of the base brake system. The ABS system, particularly the Integrated Control Unit (ICU), should only be bled when the ICU is replaced or it is removed from the vehicle. The ICU must also always be bled if for any reason it is suspected that the ICU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic 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 the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ITT Teves Mark 20 ABS 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. This brake system can be either pressure bled or manually bled. The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires the use of the DRB Diagnostic Tester 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 pressurized bleeding equipment, refer to Bleeding Base Brakes. 1. Assemble and install all brake system components on the vehicle making sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the instrument panel to the left of the steering column cover. 3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault codes stored. If it does, remove them using the DRB. 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. 5. Using the DRB, 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 is free of any air 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 brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1167 Brake Bleeding: Service and Repair Base Brake System Bleeding CAUTION: Before removing the master cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. PRESSURE BLEEDING CAUTION: 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: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Air Trapped In Brake System 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. 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 Method For Purging Air From Brake System 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1168 Open Bleeder Screw At Least One Full Turn 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. BLEEDING WITHOUT A PRESSURE BLEEDER NOTE: Correct bleeding of the brakes hydraulic system without the use of pressure bleeding equipment will require the aid of a helper. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 1174 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming NOTE: A DRB scan tool is required for diagnosis of the airbag system. Refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures for more information. ARMING 1. Make sure no one is in the vehicle. 2. Connect battery negative terminal. 3. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 4. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 5. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 6. Using the scan tool, read and record the active diagnostic trouble code data. 7. Read and record any stored diagnostic trouble codes. 8. Refer to the proper Passive Restraint Diagnostic Test if any diagnostic trouble codes are found in Step 6 and Step 7. 9. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Air Bags 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 Air Bags to diagnose the problem. To test the airbag warning lamp operation in the cluster only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1180 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1181 Fuse: Locations Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1182 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1183 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1188 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1189 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1190 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1191 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1192 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1193 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1194 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1195 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Power Distribution Center Fusible Link: Locations Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Power Distribution Center > Page 1200 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Power Distribution Center > Page 1201 Fusible Link: Locations Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Power Distribution Center > Page 1202 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Power Distribution Center > Page 1203 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations ABS Fuses Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1209 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1210 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1211 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1212 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1213 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1214 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information Wheels: Testing and Inspection General Information Inspect wheels for: - Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. Used wheels are not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1225 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1226 - 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1227 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1231 Wheel Bearing: Service Precautions CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result Do not use on pre-1998 model year vehicles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1232 Wheel Bearing: Description and Operation CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. 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 the diagnosis and testing section and the removal and installation section in this group of the service manual for the inspection and replacement of the rear wheel bearing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1233 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1234 Wheel Bearing: Service and Repair CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result Do not use on pre-1998 model year vehicles. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1235 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 129 Nm (95 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Driveshaft Nut ...................................................................................................................................... ................................................ 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1244 Wheel Fastener: Specifications Lug Nut Torque Lug Nuts .............................................................................................................................................. ................................. 109 - 150 Nm (80 - 110 ft. lbs.) Nut Hex Size .................................................... ........................................................................................................................................................... 19 mm Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1245 Wheel Fastener: Specifications Wheel Stud Size Size ...................................................................................................................................................... ........................................................... M12 x 1.5 mm Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1246 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1247 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1248 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1249 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1250 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure 170-225 psi Max. Variation Between Cylinders 25% Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1256 Compression Check: Testing and Inspection 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 adapter 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Tightening Torque Camshaft Tightening Torque M6 Fasteners 105 in.lb M8 fasteners 250 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 75 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Dimensions Camshaft: Specifications Dimensions Bearing Bore Diameters No. 1-6 ........................................................................................................................... 26.020 - 26.041 mm (1.024 - 1.025 inch) Diametrical Bearing Clearance ............................................................................................................................... 0.069 - 0.071 mm (0.0027 - 0.003 inch) End Play ............................................................................................................ .................................................... 0.050 - 0.170 mm (0.0019 - 0.0066 inch) Bearing Journal Diameter No. 1-6 ........................................................................................................................ 25.951 - 25.970 mm (1.021 - 1.022 inch) Lift (Zero Lash) Intake ........................................................ ................................................................................................................ 8.25 mm (0.324 inch) Lift (Zero Lash) Exhaust ............................................................................................................................ .......................................... 6.52 mm (0.256 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Dimensions > Page 1268 Camshaft: Specifications Camshaft Tightening Torque Camshaft Tightening Torque M6 Fasteners 105 in.lb M8 fasteners 250 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal and Installation Camshaft: Service and Repair Removal and Installation Camshaft REMOVAL 1. Remove cylinder head cover. 2. Remove timing belt, sprockets and covers. Camshaft Bearing Cap Identification 3. Bearing caps are identified for location. Remove the outside bearing caps first. Camshaft Bearing Cap-Removal 4. Loosen the camshaft bearing cap attaching fasteners in sequence shown one camshaft at a time. CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is wider. 5. Identify the camshafts before removing from the head. The camshafts are not interchangeable. CAMSHAFT END PLAY 1. Oil camshaft journals and install camshaft WITHOUT cam follower assemblies. Install rear cam caps and tighten screws to specified torque. 2. Using a suitable tool, move camshaft as far rearward as it will go. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1271 Camshaft End Play 3. Zero dial indicator. 4. Move camshaft as far forward as it will go. 5. End play travel: 0.05 - 0.15 mm (0.002 - 0.010 inch) 6. If end play is excessive check cylinder head and camshaft for wear; replace as necessary. INSTALLATION CAUTION: Ensure that NONE of the pistons are at top dead center when installing the camshafts. Camshaft Bearing Cap Tightening Sequence 1. Remove camshaft retaining caps and lubricate bearing journals. Install cam followers and camshafts with clean oil. Install right and left camshaft bearing caps # 2 thru # 5 and right # 6. Tighten M6 fasteners to 12 Nm (105 inch lbs.) in sequence shown. Camshaft Bearing Cap Sealing 2. Apply Mopar Gasket Maker to No. 1 and No. 6 bearing caps . Install bearing caps and tighten M8 fasteners to 28 Nm (250 inch lbs.). 3. Bearing end caps must be installed before seals can be installed. 4. Install timing belt, sprockets and covers. 5. Install cylinder head cover. Camshaft Follower Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1272 REMOVAL 1. Remove cylinder head cover. 2. Remove timing belt, sprockets and covers. 3. Remove camshaft. 4. Remove cam follower assemblies from cylinder head. Keep the cam followers in the order they have been removed from the head for reassembly. Cam Follower Assembly INSPECTION Inspect the cam follower assembly for wear or damage. Replace as necessary. Cam Follower Assemblies-Installation INSTALLATION 1. Lubricate with clean oil and install cam follower assemblies in their original position on the hydraulic adjuster and valve stem. 2. Install the camshafts. 3. Install timing belt, sprockets and covers. 4. Install cylinder head cover. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1273 Camshaft: Service and Repair Cleaning and Inspection Cam Follower Assembly Inspect the cam follower assembly for wear or damage. Replace as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1274 Camshaft: Service and Repair Checking End Play 1. Oil camshaft journals and install camshaft WITHOUT cam follower assemblies. Install rear cam caps and tighten screws to specified torque. 2. Using a suitable tool, move camshaft as far rearward as it will go. Camshaft End Play 3. Zero dial indicator. 4. Move camshaft as far forward as it will go. 5. End play travel: 0.05 - 0.15 mm (0.002 - 0.010 inch). 6. If end play is excessive check cylinder head and camshaft for wear; replace as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Body Diameter .................................................................................................................................................... 15.901 - 15.913 mm (0.626 - 0.6264 inch) Plunger Travel Minimum (Dry) ............................................................................................................................................................. 3.0 mm (0.118 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1278 Lifter / 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1279 Lifter / Lash Adjuster: Service and Repair REMOVAL 1. Remove cylinder head cover. 2. Remove cam follower assembly. 3. Mark hydraulic lash adjusters for reassembly in their original position. Lash adjusters are serviced as a assembly. INSTALLATION 1. Install hydraulic lash adjuster assembly making sure adjusters are at least partially full of oil. This is indicated by little or no plunger travel when the lash adjuster is depressed. 2. Install cam follower assembly. 3. Install camshaft. 4. Install cylinder head cover. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Cam Follower Assembly Inspect the cam follower assembly for wear or damage. Replace as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Carrier to Block Bolts ........................................................................................................................... .................................................... 54 Nm (40 ft. lbs.) Gear Cover Double Ended Fastener .................................................................................................................................................... 12 Nm (105 inch lbs.) Sprockets Bolts ..................................................................................................... .............................................................................. 28 Nm (250 inch lbs.) Chain Tensioner Bolts ....... .............................................................................................................................................................. .... 12 Nm (105 inch lbs.) Carrier Cover Fasteners .............................................................................. ......................................................................................... 12 Nm (105 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > Page 1287 Balance Shaft: Service and Repair BALANCE SHAFTS REMOVAL Refer to Timing Belt Cover and Timing Belt removal to repair balance shafts carrier assembly. Chain Cover, Guide And Tensioner 1. Remove chain cover, guide, and tensioner. 2. Remove gear cover retaining stud (double ended to also retain chain guide). Remove cover and balance shaft gears. 3. Remove balance shaft gear and chain sprocket retaining screws and crankshaft chain sprocket. Drive Chain And Sprockets Remove chain and sprocket assembly. Using two wide pry bars, work the sprocket back and forth until it is off the shaft. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > Page 1288 Gear Cover And Gears 4. Remove carrier gear cover and balance shafts. 5. Remove four carrier to crankcase attaching bolts to separate carrier from engine bedplate. BALANCE SHAFT CARRIER Balance Shaft(s)-Removal/Installation REMOVAL The following components will remain intact during carrier removal. Gear cover, gears, balance shafts and the rear cover. 1. Remove chain cover and driven balance shaft chain sprocket screw. 2. Loosen tensioner pivot and adjusting screws, move driven balance shaft inboard through driven chain sprocket. Sprocket will hang in lower chain loop. 3. Remove carrier to crankcase attaching bolts to remove carrier. BALANCE SHAFT INSTALLATION Balance shaft and carrier assembly installation is the reverse of the removal procedure. During installation crankshaft to balance shaft timing must be established. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > Page 1289 Balance Shaft(s)-Removal/Installation BALANCE SHAFT TIMING 1. With balance shafts installed in carrier position carrier on crankcase and install four attaching bolts and tighten to 54 Nm (40 ft. lbs.). Gear Timing 2. Turn balance shafts until both shaft key ways are up Parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After installation gear and balance shaft keyways must be up with gear timing marks meshed. 3. Install gear cover and tighten double ended stud/washer fastener to 12 Nm (105 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > Page 1290 Crankshaft Sprocket-Installation 4. Install crankshaft sprocket using Special Tool 6052. Balance Shaft Timing 5. Turn crankshaft until number one cylinder is at Top Dead Center (TDC). The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap. 6. Place chain over crankshaft sprocket so that the nickel plated link of the chain is over the number 1 cylinder timing mark on the crankshaft sprocket. 7. Place balance shaft sprocket into the timing chain so that the timing mark on the sprocket (yellow dot) mates with the (lower) nicked plated link on the chain 8. With balance shaft keyways pointing up (12 o'clock) slide the balance shaft sprocket onto the nose of the balance shaft. The balance shaft may Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications > Page 1291 have to be pushed in slightly to allow for clearance. NOTE: THE TIMING MARK ON THE SPROCKET THE (LOWER) NICKEL PLATED LINK, AND THE ARROW ON THE SIDE OF THE GEAR COVER SHOULD LINE UP WHEN THE BALANCE SHAFTS ARE TIMED CORRECTLY. 9. If the sprockets are timed correctly install the balance shaft bolts and tighten to 28 Nm (250 inch lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation. CHAIN TENSIONING 1. Install chain tensioner loosely assembled. 2. Position guide on double ended stud making sure tab on the guide fits into slot on the gear cover. Install and tighten nut/washer assembly to 12 Nm (105 inch lbs.). Chain Tension Adjustment 3. Place a shim 1 mm (0.039 inch) thick x 70 mm (2.75 inch) long or between tensioner and chain. Push tensioner and shim up against the chain.Apply firm pressure (5.5 to 6.6 lbs.) directly behind the adjustment slot to take up all slack. Chain must have shoe radius contact. 4. With the load applied, tighten top tensioner bolt first, then bottom pivot bolt. Tighten bolts to 12 Nm (105 inch lbs.). Remove shim. 5. Install carrier covers and tighten screws to 12 Nm (105 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications CLEARANCE: New Part .............................................................................................................................................. .................. 0.025 - 0.071 mm (0.001 - 0.003 inch) Wear Limit ........................................................... .......................................................................................................................... 0.075 mm (0.003 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings Connecting Rod Bearing: Service and Repair Fitting Connecting Rod Bearings 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. Measuring Plastigage Width 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 rod 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 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. 6. Plastigage is available in a variety of clearance ranges. The 0.025 - 0.076 mm (0.001 - 0.003 inch) is usually the most appropriate for checking engine bearing proper specifications. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1297 Connecting Rod Bearing: Service and Repair Main Bearing and Connecting Rod Bearing Clearances 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. Engine With 5 Main Bearings 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 & 5 main bearing. - When checking # 5 main bearing shim # 4 main bearing. Engine With 4 Main Bearing 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. NOTE: 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. Plastically Placed In Lower Shell 2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 inch) off center and away from the oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1298 Clearance Measurement 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. 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. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. 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. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds 0.076 mm (0.003 inch) replace bearing. 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 (L4-2.4L VIN X (1998)) 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 27 Nm PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1303 Connecting Rod: Specifications Connecting Rod Specifications GENERAL SPECIFICATIONS Bearing Clearance ............................................................................................................................................. 0.025 0.071 mm (0.0009 - 0.0027 inch) Piston Pin Bore Diameter .................................................................................................................................. 20.96 - 20.98 mm (0.8252 - 0.8260 inch) Large End Bore Diameter ..................................................................................................................................... 53.007 52.993 mm (2.0868 - 2.0863) Side Clearance ................................................................................................................................................. 0.013 0.0150 mm (0.0051 - 0 0150 inch) Total Weight (Less Bearing) ........................................................................................................................................................ 565.8 grams (19.96 oz.) TORQUE SPECIFICATIONS Connecting Rod Cap Bolts ............................................................................................................................................. 27 Nm (20 ft. lbs.) Plus 1/4 Turn Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1304 Connecting Rod: Service and Repair NOTE: Cylinder Head must be removed before Pistons and Rods. Piston Markings 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Mark piston with matching cylinder number Identify Connecting Rod To Cylinder 2. Remove oil pan. Scribe the cylinder number on the side of the rod and cap for identification. 3. Pistons have a directional stamping in the front half of the piston facing towards the front of engine. 4. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 5. Remove Balance Shaft Assembly. 6. Remove connecting rod cap bolts. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 7. After removal, install bearing cap on the mating rod. 8. Piston and Rods are serviced as an assembly. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1305 Piston Ring End Gap Position 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located. As viewed from top. Piston-Installation 3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. 4. The directional stamp on the piston should face toward the front of the engine. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. NOTE: The connecting rod cap bolts should not be reused. 7. Before installing the NEW bolts the threads should be coated with clean engine oil. 8. Install each bolt finger tight than alternately torque each bolt to assemble the cap properly. CAUTION: Do not use a torque wrench for second part of last step. 9. Tighten the bolts to 27 Nm PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1306 Checking Connecting Rod Side Clearance 10. Using a feeler gauge, check connecting rod side clearance. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications Crankshaft Main Bearing: Specifications Rebuild Specifications GENERAL SPECIFICATIONS Main Bearing Journals Diameter ........................................................................................................................................................ 59.992-60.008 mm (2.361-2.3625 inch) Out-of-Round (Max.) ........................................................................................................................................................... 0.0035 mm (0.0001 inch) Taper (Max.) ............................................................................................... ................................................................................ 0.0038 (0.0001 inch) TORQUE SPECIFICATIONS Cap Bedplate M8 Bedplate Bolts ............................................................................................................................... ..................................... 34 Nm (250 inch lbs.) M11 Main Cap Bolts ................................................................................................................................................. 41 Nm (30 ft. lbs. plus 1/4 turn) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications > Page 1311 Crankshaft Main Bearing: Specifications Torque Specifications Mounting Bolts ..................................................................................................................................... ............................... 41 Nm (30 ft. lbs.) plus 1/4 turn Turning Torque With Bedplate installed .............................................................................................................................................. 5.6 Nm (50 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection Crankshaft Main Bearing: Service and Repair Inspection 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. Engine With 5 Main Bearings 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 & 5 main bearing. - When checking # 5 main bearing shim # 4 main bearing. Engine With 4 Main Bearing 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. NOTE: 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. Plastically Placed In Lower Shell 2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 inch) off center and away from the oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection > Page 1314 Clearance Measurement 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. 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. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. 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. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds 0.076 mm (0.003 inch) replace bearing. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection > Page 1315 Crankshaft Main Bearing: Service and Repair Fitting Bearings Main Bearing Identification CRANKSHAFT MAIN BEARINGS The crankshaft is supported in five main bearings. All upper and lower bearing shells in the crankcase have oil grooves. The number three lower main thrust bearing is plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal. Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersized: 0.025 mm (0.001 inch) and 0.250 mm (0.010 inch). Never install an undersize bearing that will reduce clearance below specifications. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection > Page 1316 Installing Main Bearing Upper Shell MAIN BEARING INSTALLATION 1. Install the main bearing shells with the lubrication groove in the cylinder block. 2. Make certain oil holes in block line up with oil holes in bearings. Bearing tabs must seat in the block tab slots. CAUTION: Do not get oil on the bedplate mating surface. It may effect the sealer ability to seal the bedplate to cylinder block. 3. Oil the bearings and journals and install crankshaft. CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. Ensure that both cylinder block and bedplate surfaces are clean. Main Bearing Caps/Bedplate Sealing 4. Apply 1.5 to 2.0 mm (0.059 to 0.078 inch) bead of anaerobic sealer Mopar Torque Cure Gasket Maker to cylinder block. 5. Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block. 6. Before installing bolts, lubricate the threads with clean engine oil, wipe off any excess oil. 7. Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block. 8. To ensure correct thrust bearing alignment, perform the following steps: - Step 1: Rotate crankshaft until number 4 piston is at TDC. - Step 2: Move crankshaft rearward to limits of travel. - Step 3: Then, move crankshaft forward to limits of travel. - Step 4: Wedge an appropriate tool between the rear of the cylinder block (NOT BED PLATE) and the rear crankshaft counterweight. This will hold the crankshaft in it's furthest forward position. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection > Page 1317 Main Bearing Caps/Bedplate Torque Sequence - Step 5: Install and tighten bolts (1 - 10) in sequence to 41 Nm (30 ft. lbs.). - Step 6: Remove wedge tool used to hold crankshaft. 9. Tighten bolts (1 - 10) again to 41 Nm (30 ft. lbs.) + 1/4 turnin sequence. 10. Install main bearing bedplate to engine block bolts (11 through 20), and torque each bolt to 28 Nm (20 ft. lbs.) in sequence. 11. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 Nm (50 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Connecting Rod Journal Diameter ...................................................................................................................... 49.984 - 50.000 mm (1.967 - 1.9685 inch) Out-of-Round (Max.) ......................................................................................... ............................................................................ 0.0035 mm (0.0001 inch) Taper (Max.) .................. .............................................................................................................................................................. .. 0.0038 mm (0.0001 inch) Main Bearing Diametrical Clearance No. 1 - 5 .................................................................................................... 0.018 - 0.058 mm (0.0007 - O.0023 inch) End Play ..................................................................................................................................... ............................... 0.09 - 0.24 mm (0.0035 - 0.0094 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 REMOVAL NOTE: Crankshaft can not be removed when engine is in vehicle. 1. Remove oil filter and oil pan. 2. Remove Timing Belt Cover, Timing Belt and Oil Pump. 3. Remove Balance Shafts Assembly. 4. Remove all main bearing cap bedplate bolts from the engine block. 5. Using a mallet gently tap the bedplate loose from the engine block dowel pins. CAUTION: Do not pry up on one side of the bedplate. Damage may occur to cylinder block to bedplate alignment and thrust bearing. 6. Bedplate should be removed evenly from the cylinder block dowel pins to prevent damage to the dowel pins and thrust bearing. 7. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft. INSTALLATION Installing Main Bearing Upper Shell 1. Install the main bearing shells with the lubrication groove in the cylinder block. 2. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. CAUTION: Do not get oil on the bedplate mating surface. It may effect the sealer ability to seal the bedplate to cylinder block. 3. Oil the bearings and journals. Install crankshaft. CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1323 Main Bearing Caps/Bedplate Sealing 4. Apply 1.5 to 2.0 mm (0.059 to 0.078 inch) bead of Mopar Torque Cure Gasket Maker to cylinder block. 5. Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block. 6. Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil. 7. Install main bearing bedplate to engine block bolts 11, 17 and 20 finger tight. Tighten these bolts down together until the bedplate contacts the cylinder block. 8. To ensure correct thrust bearing alignment, perform the following steps: - Step 1: Rotate crankshaft until number 4 piston is at TDC. - Step 2: Move crankshaft rearward to limits of travel. - Step 3: Then, move crankshaft forward to limit of travel. - Step 4: Wedge an appropriate tool between the rear of the cylinder block (NOT BED PLATE) and the rear crankshaft counterweight. This will hold the crankshaft in it's furthest forward position. Main Bearing Caps/Bedplate Torque Sequence - Step 5: Install and tighten bolts (1-10) in sequence to 41 Nm (30 ft. lbs.) - Step 6: Remove wedge tool used to hold crankshaft. 9. Tighten bolts (1 - 10) again to 41 Nm (30 ft. lbs.) + 1/4 turn in sequence. 10. Install main bearing bedplate to engine block bolts (11 through 20), and torque each bolt to 28 Nm (20 ft. lbs.) in sequence. 11. After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 Nm (50 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1324 Crankshaft: Service and Repair Cleaning and Inspection Crankshaft Journal Measurements The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out of round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of Number 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1325 Crankshaft: Service and Repair Service Procedures Checking Crankshaft End Play-Typical 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. OPTIONAL CRANKSHAFT END PLAY CHECK 1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek, using care not to damage any bearing surface. DO NOT loosen main bearing cap. 2. Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Description and Operation Engine Block Heater: Description and Operation Engine Block Heater 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Description and Operation > Page 1330 Engine Block Heater: Description and Operation General Information On all models an engine block heater is available as an optional accessory. The heater, operated by ordinary house current (110 Volt A.C.) through a power cord and connector behind the radiator grille. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1331 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 110 volt test light; test heater element continuity with an ohmmeter or 12-volt test light. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1332 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 Engine Block Heaters 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair REMOVAL Core Hole Plug 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 remove all rust and 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Crankshaft Pulley Torque Specification 135 Nm (100 ft.lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley > Page 1340 Harmonic Balancer - Crankshaft Pulley: Specifications Harmonic Balancer/Vibration Damper Damper Bolt ......................................................................................................................................... ................................................ 135 Nm (100 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1341 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Damper-Removal REMOVAL Remove crankshaft damper bolt. Remove damper by using Special Tool 1026 and Insert 6827-A. Crankshaft Damper-Installation INSTALLATION Install crankshaft damper using M12 1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft vibration damper bolt and tighten to 142 Nm (105 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Clearance at 14 mm (9/16 inch) From Bottom of Skirt ....................................................................................... (0.024 - 0.057 mm (0.0009 - 0.0022 inch) Weight ................................................................................................................................................. .......................... 332 - 346 grams (11.85 - 12.20 oz.) Top Land Clearance (Diametrical) ............................................................................................................................ 0.614 - 0.664 mm (0.024 - 0.026 inch) Piston Length ...................................................................................................... ............................................................................... 60.30 mm (2.374 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1345 Piston: Service and Repair NOTE: Cylinder Head must be removed before Pistons and Rods. Piston Markings 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Mark piston with matching cylinder number Identify Connecting Rod To Cylinder 2. Remove oil pan. Scribe the cylinder number on the side of the rod and cap for identification. 3. Pistons have a directional stamping in the front half of the piston facing towards the front of engine. 4. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 5. Remove Balance Shaft Assembly. 6. Remove connecting rod cap bolts. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 7. After removal, install bearing cap on the mating rod. 8. Piston and Rods are serviced as an assembly. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1346 Piston Ring End Gap Position 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located. As viewed from top. Piston-Installation 3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. 4. The directional stamp on the piston should face toward the front of the engine. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. NOTE: The connecting rod cap bolts should not be reused. 7. Before installing the NEW bolts the threads should be coated with clean engine oil. 8. Install each bolt finger tight than alternately torque each bolt to assemble the cap properly. CAUTION: Do not use a torque wrench for second part of last step. 9. Tighten the bolts to 27 Nm PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1347 Checking Connecting Rod Side Clearance 10. Using a feeler gauge, check connecting rod side clearance. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Clearance in Piston ............................................................................................................................. ....................................................... 0.005 - 0.018 mm In Rod (Interference) ............................................................................................................................................. 0.018 0.043 mm (0.0007 - 0.0017 inch) Diameter ............................................................................................................................................................ 21.998 - 22.003 mm (0.8660 - 0.8662 inch) End Play ......................................................................... ............................................................................................................................................... None Length .................................................................................................................................................. ..................... 72.75 - 73.25 mm (2.864 - 2.883 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring Groove Depth No. 1 .................................................................................................................................................... .................. 4.640 - 4.784 mm (0.182 - 0.188 inch) No. 2 .................................................................... .................................................................................................. 4.575 - 4.719 mm (0.180 - 0.185 inch) No. 3 ........................................................................................................................................... ........................... 4.097 - 4.236 mm (0.161 - 0.166 inch) Piston Ring Gap Top Compression Ring ........................................................................................................................................... 0.25 - 0.51 mm (0.0098 - 0.020 inch) 2nd Compression Ring .............................................................................................................................................. 0.23 0.48 mm (0.009 - 0.018 inch) Oil Control (Steel Rails) .......................................................................................................................................... 0.25 - 0.64 mm (0.0098 - 0.025 inch) Piston Ring Side Clearance Top and Second Compression Rings ................................................................................................................. 0.030 - 0.080 mm (0.0011 0.0031 inch) Oil Ring (Pack) ................................................................................................................................................. 0.012 0.178 mm (0.0004 - 0.0070 inch) Piston Ring Width Compression Rings ................................................................................................................................................... 1.47 1.50 mm (0.057 - 0.059 inch) Oil Ring (Pack) ....................................................................................................................................................... 2.72 - 2.88 mm (0.107 - 0.1133 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1354 Piston Ring: Service and Repair Piston Ring Gap 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge. Piston Ring Side Clearance Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1355 2. Check piston ring to groove side clearance. Piston Ring Installation PISTON RINGS-INSTALLATION 1. Install rings with manufacturers I.D. 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. Installing Side Rail 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1356 Piston Ring End Gap Position 5. Position piston ring end gaps. 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. Staggering ring gap is important for oil control. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this engine has hydraulic lifters or adjusters which do not require nor have provisions for adjustment. See "Rocker Arm: Service and Repair" for further information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1364 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Cam Follower Assembly Inspect the cam follower assembly for wear or damage. Replace as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Bolts ..................................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1371 Valve Cover: Service and Repair Ignition Coil Pack And Ground Strap REMOVAL 1. Remove ignition coil pack and plug wires. Remove ground strap. 2. Remove the cylinder head cover fasteners. 3. Remove cylinder head cover from cylinder head. INSTALLATION NOTE: Replace spark plug well seals when installing a new cylinder head cover gasket. Cylinder Head Cover Gasket And Spark Plug Seals 1. Install new cylinder head cover gaskets and spark plug seals. CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. 2. Apply Mopar Silicone Rubber Adhesive Sealant at the camshaft cap corners and at the top edge of the 1/2 round seal. Cylinder Head Cover Tightening Sequence Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1372 3. Install cylinder head cover assembly to head and tighten fasteners in sequence. Using the 3 step torque method: a) Tighten all fasteners to 4.5 Nm (40 inch lbs.) b) Tighten all fasteners to 9.0 Nm (80 inch lbs.) c) Tighten all fasteners to 12 Nm (105 inch lbs.) 4. Install ignition coil pack and plug wires. Tighten fasteners to 12 Nm (105 inch lbs.). 5. Install ground strap. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle ................................................................................................................................................... ............................................................................. 45° Runout (Max.) ...................................................................................................................................... ............................................. 0.050 mm (0.002 inch) Width (Finish) Intake and Exhaust .................................................................................................................................... 0.9 - 1.3 mm (0.035 - 0.051 inch) Guide Bore Diameter (STD) ................................................................................................................................... 11.0 - 11.02 mm (0.4330 - 0.4338 inch) Finish Guide Bore ID ................................................................................................................................................ 5.975 6.000 mm (0.235 - 0.236 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length (Approximately) .............................................................................................................................................................. 48.4 mm (1.905 inch) Spring Tension (Valve Closed) ........................................................................................... 338 N ± 20 N @ 38.0 mm (75.98 lbs. ± 4.5 lbs. @ 1.496 inch) Spring Tension (Valve Open) ........................................................................................................ 607 N ± 30 N @ 29.75 mm (136 lbs. ± 7 @ 1.172 inch) Number of Coils ............................................................................................... ............................................................................................................... 7.82 Wire Diameter .............. .............................................................................................................................................................. ......... 3.86 mm (0.151 inch) Installed Spring Height ........................................................................... ........................................................................................... 38.00 mm (1.496 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 cylinder head removed, compress valve springs using a universal valve spring compressor. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. 4. Inspect and clean the valves. INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. Valve Stem Oil Seal Tool 2. Install new valve stem seals on all valves using a valve stem seal tool. The valve stem seals should be pushed firmly and squarely over valve guide. CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves. 3. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to miss-align 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. Ensure both locks are in the correct location after removing tool. Checking Spring Installed Height And Valve Tip Height Dimensions 4. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 inch), install a 0.762 mm (0.030 inch) spacer under the valve spring seat to bring spring height back within specification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1381 Valve Spring: Service and Repair Cylinder Head On REMOVAL 1. Remove camshafts. 2. Rotate crankshaft until piston is at TDC on compression. 3. With air hose attached to adapter tool installed in spark plug hole, apply 90 - 120 psi air pressure. Valve Spring-Removal/Installation 4. Using Special Tool MD-998772-A with adapter 6779 compress valve springs and remove valve locks. 5. Remove valve spring. 6. Remove valve stem seal by a using valve stem seal tool. INSTALLATION Valve Stem Seal/Valve Spring Seat 1. Install valve seal/valve spring seat assembly. Push the assembly down to seat it onto the valve guide. 2. Install valve spring and retainer, use Special Tool MD-998772-A with adapter 6779 to compress valve springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems. 3. Remove air hose and install spark plugs. 4. Install camshafts. 5. Install cylinder head cover. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1382 Valve Spring: Service and Repair Inspection VALVES 1. Clean valves thoroughly and discard burned, warped and cracked valves. 2. Measure valve stems for wear. Measure stem about 60 mm beneath the valve lock grooves. 3. If valve stems are worn more than 0.05 mm (0.002 inch), replace valve. VALVE SPRINGS 1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct tension. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: Valve Closed Nominal Tension - 76 lbs. @ 38.0 mm (1.50 inch) - Valve Open Nominal Tension - 136 lbs. @ 29.75 mm (1.17 inch) 2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Face Angle .......................................................................................................................................... ............................................................... 44-1/2° - 45° Head Diameter Intake ............................................................................................................................................... 34.67 34.93 mm (1.364 - 1.375 inch) Head Diameter Exhaust ............................................................................................................................................. 30.37 30.63 mm (1.195 - 1.205 inch) Length-Intake (Overall) ......................................................................................................................................... 112.76 113.32 mm (4.439 - 4.461 inch) Length-Exhaust (Overall) ...................................................................................................................................... 109.59 110.09 mm (4.314 - 4.334 inch) Valve Margin-Intake ................................................................................................................................................. 1.285 1.615 mm (0.050 - 0.063 inch) Valve Margin-Exhaust .............................................................................................................................................. 0.985 1.315 mm (0.038 - 0.051 inch) Valve Stem Tip Height-Intake ........................................................................................................................................................... 48.04 mm (1.891 inch) Valve Stem Tip Height-Exhaust ........................................................................................................................................................ 47.99 mm (1.889 inch) Stem Diameter-Intake ................................................................................................................................................ 5.934 5.952 mm (0.234 - 0.234 inch) Stem Diameter-Exhaust ............................................................................................................................................. 5.906 5.924 mm (0.233 - 0.233 inch) Stem-to-Guide Clearance-Intake ........................................................................................................................... 0.048 - 0.066 mm (0.0018 - 0.0025 inch) Stem-to-Guide Clearance-Exhaust ...................................................................................................................... 0.0736 - 0.094 mm (0.0029 - 0.0037 inch) Max. Allowable Stem-to-Guide Clearance Intake and Exhaust ......................................................................................................... 0.025 mm (0.010 inch) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1386 Valve: Testing and Inspection VALVES 1. Clean valves thoroughly and discard burned, warped and cracked valves. 2. Measure valve stems for wear. Measure stem about 60 mm beneath the valve lock grooves. 3. If valve stems are worn more than 0.05 mm (0.002 inch), replace valve. VALVE SPRINGS 1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct tension. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: Valve Closed Nominal Tension - 76 lbs. @ 38.0 mm (1.50 inch) - Valve Open Nominal Tension - 136 lbs. @ 29.75 mm (1.17 inch) 2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1387 Valve: Service and Repair REMOVAL 1. With cylinder head removed, compress valve springs using a universal valve spring compressor. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. 4. Inspect and clean the valves. INSTALLATION 1. Coat valve stems with clean engine oil and insert in cylinder head. Valve Stem Oil Seal Tool 2. Install new valve stem seals on all valves using a valve stem seal tool. The valve stem seals should be pushed firmly and squarely over valve guide. CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves. 3. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to miss-align 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. Ensure both locks are in the correct location after removing tool. Checking Spring Installed Height And Valve Tip Height Dimensions 4. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 inch), install a 0.762 mm (0.030 inch) spacer under the valve spring seat to bring spring height back within specification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions Drive Belt: Technical Service Bulletins Engine/Electrical - Belt Tension/Connector Revisions NUMBER: 26-04-98 GROUP: Miscellaneous DATE: April, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1998 Cirrus, Stratus, Breeze Service Manual - Publication Number 81-270-8121 DESCRIPTION OF CHANGES Adds a note referencing belt tension adjustment Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions > Page 1393 7-27 Revises the C121 connector pin outs Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions > Page 1394 8W-80-11 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions > Page 1395 Drive Belt: Technical Service Bulletins Engine - Drive Belt Tension Revisions NUMBER: 26-02-98 GROUP: Miscellaneous DATE: February, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1998 Cirrus/Stratus/Breeze Service Manual - Publication Number 81-270-8121 DESCRIPTION OF CHANGES Revised belt tension specifications Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine/Electrical - Belt Tension/Connector Revisions > Page 1396 7-29 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1397 Drive Belt: Description and Operation Drive Belts - All Engines The engines are equipped with 2 accessory drive belts. One belt drives the power steering pump, the other drives the generator and air conditioning. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1398 Drive Belt: Testing and Inspection Accessory Drive Belt Diagnosis Satisfactory performance of the belt driven accessories depends on belt condition and proper belt tension. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1399 Drive Belt: Adjustments For conventional belts and Poly-V belts, use belt tensioning Special Tool Kit C-4162 to obtain proper belt tension. Belt Tension Gauge Method Adjust the belt tension for a New or Used belt as prescribed. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation Drive Belt: Service and Repair Removal and Installation The content of this article reflects changes called for in TSB 26-04-98. AIR CONDITIONING COMPRESSOR AND GENERATOR BELT Accessory Drive Belt System - All Engines Accessory Drive Belt System - All Engines 1. Loosen T-Bolt locking nut A and pivot bolt B to remove and install Poly V belt and/or adjust belt tension. 2. Tighten adjusting bolt to adjust belt tension to specification. Air Conditioning Compressor And Generator Belt Adjustment 3. Tighten T-Bolt locking nut A and pivot bolt B to 54 Nm (40 ft. lbs.). POWER STEERING PUMP BELT 1. From the top of the vehicle loosen pivot bolt C. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1402 Power Steering Belt Adjustment 2. From under the vehicle loosen locking bolts D and E. 3. Install the belt. Adjust belt tension with 1/2 inch breaker bar installed in adjusting bracket. NOTE: For accessory drive belt specifications, See: Adjustments 4. Tighten locking bolt D to 54 Nm (40 ft. lbs.). 5. Tighten locking bolt E and the pivot bolt C to 54 Nm (40 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1403 Drive Belt: Service and Repair Cleaning and Inspection Belt replacement under any or all of the following conditions is required, excessive wear, frayed cords or severe glazing. Drive Belt Wear Pattern Poly-V-Belt system may develop minor cracks across the ribbed side. These minor cracks are considered normal and acceptable. Cracks parallel are not. NOTE: Do not use any type of belt dressing or restorer on Poly-V-Belts. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Bracket-Right Bolts .............................................................................................................................. .................................................... 61 Nm (45 ft. lbs.) Front & Rear Through Bolt ................................ ...................................................................................................................................... 61 Nm (45 ft. lbs.) Front Bending Strut Long Bolts .............................................................................................................................................................. 101 Nm (75 ft. lbs.) Front Bending Strut Short Bolt ............................................................................. .................................................................................... 61 Nm (45 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1407 Engine Mount: Adjustments 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. ENGINE SUPPORT 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front and Rear Mounts Engine Mount: Service and Repair Front and Rear Mounts REMOVAL Front Mount 1. Raise vehicle on hoist. Engine Mounting-Front 2.4L Engine 2. Remove through bolt at front mount (Fig. 17). 3. Remove attaching bolts from mount to lower radiator support. NOTE: It may be necessary to tilt engine for front mount removal clearance. 4. Remove mount. Rear Mount 1. Raise vehicle on hoist. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front and Rear Mounts > Page 1410 Engine Mounting-Rear 2.4L Engine 2. Remove through bolt (A) from rear engine mount and bracket (Fig. 18). Engine Mounting-Front And Rear 3. Remove rear strut bracket and brace (Fig. 16). 4. Remove bolts attaching rear mount to suspension crossmember. NOTE: It may be necessary to tilt engine for rear mount removal clearance. 5. Remove rear mount. INSTALLATION Front Mount 1. Position front mount. Position damper weight (some models) and install front mount to lower radiator support crossmember attaching bolts. Tighten bolts to 61 Nm (45 ft. lbs.). 2. Install through bolt and tighten to 61 Nm (45 ft. lbs.). 3. Lower vehicle. Rear Mount 1. Position rear mount. 2. Install bolts attaching rear mount to crossmember. Tighten bolts to 61 Nm (45 ft. lbs.). 3. Install rear strut and support brackets. Tighten bolts to the following torque values: - Bolts attaching strut bracket to front suspension crossmember: 61 Nm (45 ft. lbs.) - Nut attaching support bracket to front suspension crossmember: 108 Nm (80 ft. lbs.) - Bolt attaching support bracket to rear strut: 61 Nm (45 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front and Rear Mounts > Page 1411 4. Tighten through bolt (A) at rear mount to 61 Nm (45 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front and Rear Mounts > Page 1412 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. REMOVAL 1. Support the transmission with a transmission jack. Left Side Mount-Typical 2. Remove the three vertical bolts (A) from the mount to the transmission bracket. 3. Remove the mount to frame rail fasteners (B) and remove mount. INSTALLATION 1. Install mount. Tighten mount to frame rail fasteners (B) to 33 Nm (24 ft. lbs.). 2. Install mount to transmission bracket vertical bolts (A). Tighten to 61 Nm (45 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front and Rear Mounts > Page 1413 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. Engine Mounting-Right Side 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front and Rear Mounts > Page 1414 Engine Mount: Service and Repair Structural Collar REMOVAL 1. Raise vehicle on hoist. 2. Remove front engine torque bracket from bending strut and front insulator mount. 3. Remove bolts attaching bending strut to engine and transaxle. 4. Remove bolts attaching collar and strut to engine, oil pan, and transaxle. Remove strut and collar. INSTALLATION CAUTION: Torque procedure for the structural collar and bending strut must be followed or damage could occur to oil pan, collar, and/or bending strut. Structural Collar And Bending Strut-Removal And Installation 1. Perform the following steps for installing structural collar and bending strut. - Step 1: Place collar into position between transaxle and oil pan. Install collar to transaxle bolt 1, hand start only. - Step 2: Install collar to oil pan bolt 4, hand tight only. - Step 3: Position bending strut in place and hand start only bolt 3 into the upper transaxle hole. - Step 4: Install bolt 2, through strut and collar. Hand start only. - Step 5: Install bolt 6, strut to cylinder block, hand tight only. - Step 6: Install the remaining collar to oil pan bolt 5, hand tight only. - Step 7: Final torque collar to transaxle bolts 13, to 101 Nm (75 ft. lbs.). - Step 8: Install bolts 7 and 8, through strut and into cylinder block. - Step 9: Final torque bolts 4 - 8 to 61 Nm (45 ft. lbs.). 2. Install front torque bracket. Tighten torque bracket to bending strut bolts to 33 Nm (24 ft. lbs.) and front engine mount through bolt to 61 Nm (45 ft. lbs.). 3. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure At Curb Idle Speed 4 psi CAUTION: If pressure is ZERO at curb Idle, DO NOT run engine at 3,000 rpm. At 3000 rpm 25 - 80 psi CAUTION: If pressure is ZERO at curb Idle, DO NOT run engine at 3,000 rpm. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1419 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE 1. Remove oil pressure sending unit and install gauge assembly C-3292. 2. Run engine until thermostat opens. CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM 3. Oil Pressure: Curb Idle 25 kPa (4 psi) minimum 3000 RPM 170/550 kPa (25/80 psi). 4. If oil pressure is 0 at idle. Shut off engine, check for pressure relief valve stuck open or a clogged oil pickup screen. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 ............................................................................................................................... ............................................................. 4.7L (5.0 Qt) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1424 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1425 Engine Oil: Description and Operation 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. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPAR provides engine oils that conforms to this service grade. Temperature/Engine Oil Viscosity SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. 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. Engine Oil Container Standard Notations 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1426 Engine Oil: Testing and Inspection The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. Oil Level Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Add only when the level is at or below the ADD mark. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1427 Engine Oil: Service and Repair CHANGING ENGINE OIL Change engine oil at mileage and time intervals. 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. 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. 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. ENGINE OIL FILTER CHANGE Filter Specification All engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar or equivalent oil filter be used. 0il Filter Removal Refer to Removal and Installation procedure. Used Engine 0il Disposal Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Description and Operation > Automatic Transmission Oil Coolers Oil Cooler: Description and Operation Automatic Transmission Oil Coolers Transmission Oil Cooler Oil coolers are internal oil to coolant type, mounted in the radiator left tank. Rubber oil lines feed the oil cooler and the automatic transmission. Use only approved transmission oil cooler hose. Since these hoses are molded to fit space available, replacement molded hoses are recommended. Tighten Oil Cooler Hose Clamps to 2 Nm (18 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Description and Operation > Automatic Transmission Oil Coolers > Page 1432 Oil Cooler: Description and Operation External Transmission Oil Cooler Transmission Oil Cooler - 2.0/2.4L Engine Transmission Oil Cooler - 2.5L Engine An external oil-to-air type transmission oil cooler is mounted ahead of the cooling module. This style of cooler uses steel tubes and rubber oil lines to feed oil from the internal (in radiator tank) cooler to the external cooler and then to the automatic transmission. Use only approved transmission oil cooler hose. Since these hoses are molded to fit space available, replacement molded hoses are recommended. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Filter ..................................................................................................................................................... .................................................... 20 Nm (15 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1436 Oil Filter: Service and Repair CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Turn counterclockwise to remove. 2. To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until the gasket contacts base. Tighten to 21 Nm (15 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts ..................................................................................................................................................... ........................................... 12 Nm (105 inch lbs.) Drain Plug ............................................................. ............................................................................................................................... 27 Nm (20 ft. lbs.) Collar to Pan Bolts and Transaxle Bolts Step 1. Place collar into position between transaxle and oil pan. Install collar to transaxle bolt 1, hand tight only. Step 2. Install collar to oil pan bolt 4, hand tight only. Step 3. Position bending strut in place and hand tight only bolt 3 into upper transaxle hole. Step 4. Install bolt 2, through strut and collar.Hand start only. Step 5. Install bolt 6, strut to cylinder block, hand tight only. Step 6. Install remaining collar to oil pan bolt 5, hand tight only. Step 7. Final torque collar to transaxle bolts 1 - 3, to 101 Nm (75 ft. lbs.). Step 8. Install bolts 7 and 8, through strut and into cylinder block. Step 9. Final torque bolts 4 - 8 to 61 Nm (45 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1440 Oil Pan: Service and Repair REMOVAL 1. Raise vehicle on hoist and drain engine oil. 2. Remove front engine torque bracket from bending strut and insulator mount. Structural Collar And Bending Strut-Removal And Installation 3. Remove bolts attaching collar and bending strut to engine, oil pan, and transaxle. Remove strut and collar. 4. Remove oil pan. 5. Clean oil pan and all gasket surfaces. INSTALLATION Oil Pan Sealing 1. Apply Mopar Silicone Rubber Adhesive Sealant or equivalent at the oil pump to engine block parting line. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1441 Oil Pan Gasket Installation 2. Install the oil pan gasket to the block. 3. Install pan and tighten the screws to 12 Nm (105 inch lbs.). CAUTION: Torque procedure for the structural collar and bending strut must be followed or damage could occur to oil pan, collar, and/or bending strut. 4. Perform the following steps for installing structural collar and bending strut. - Step 1: Place collar into position between transaxle and oil pan. Install collar to transaxle bolt 1, hand start only. - Step 2: Install collar to oil pan bolt 4, hand tight only. - Step 3: Position bending strut in place and hand start only bolt 3 into the upper transaxle hole. - Step 4: Install bolt 2, through strut and collar. Hand start only. - Step 5: Install bolt 6, strut to cylinder block, hand tight only. - Step 6: Install the remaining collar to oil pan bolt 6, hand tight only. - Step 7: Final torque collar to transaxle bolts 1 - 3, to 101 Nm (75 ft. lbs.) - Step 8: Install bolts 7 and 8, through strut and into cylinder block. - Step 9: Final torque bolts 4 - 8 to 61 Nm (45 ft. lbs.). 5. Install front torque bracket. Tighten torque bracket to bending strut bolts to 33 Nm (24 ft. lbs.) and front engine mount through bolt to 61 Nm (45 ft. lbs.). 6. Lower vehicle and fill engine crankcase with proper oil to correct level. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations 2.4L Engine Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure At Curb Idle Speed 4 psi CAUTION: If pressure is ZERO at curb Idle, DO NOT run engine at 3,000 rpm. At 3000 rpm 25 - 80 psi CAUTION: If pressure is ZERO at curb Idle, DO NOT run engine at 3,000 rpm. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1449 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE 1. Remove oil pressure sending unit and install gauge assembly C-3292. 2. Run engine until thermostat opens. CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM 3. Oil Pressure: Curb Idle 25 kPa (4 psi) minimum 3000 RPM 170/550 kPa (25/80 psi). 4. If oil pressure is 0 at idle. Shut off engine, check for pressure relief valve stuck open or a clogged oil pickup screen. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1454 Intake Manifold: Specifications Resonator Bolt to Intake Manifold 44 in.lb EGR Tube to Intake Manifold 79 in.lb Intake Manifold Bolts 200 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1455 Intake Manifold: Description and Operation The intake manifold is a tuned aluminum casting with individual primary runners leading from a plenum to the cylinders. The manifold is designed to boost torque which is desired for excellent; engine response and usable power output. The intake manifold is also cored with an EGR passage for balanced cylinder to cylinder EGR distribution. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1456 Intake Manifold: Testing and Inspection 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1457 Intake Manifold: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE WARNING: Release fuel system pressure before servicing system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. REMOVAL 1. Perform fuel system pressure release procedure before attempting any repairs. Auxiliary Jumper Terminal 2. Disconnect negative cable from auxiliary jumper terminal. 3. Remove Air Inlet Resonator. 4. Disconnect the fuel supply line quick connect at the fuel rail assembly. WARNING: Wrap shop towels around hose to catch any gasoline spillage. 5. Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine. Cover injector holes with a suitable covering. CAUTION: Do not set fuel injectors on their tips, damage may occur to the injectors 6. Remove accelerator, kickdown and speed control cables from throttle lever and bracket. Idle Air Control (IAC) Motor, Throttle Position Sensor (TPS) Wiring Connectors, And Vacuum Hose Connection 7. Disconnect idle air control (IAC) motor and throttle position sensor (TPS) wiring connectors. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1458 Intake Air Temperature Sensor, Leak Detection Pump, And PCV Hoses - 2.4L Engine 8. Disconnect intake air temperature sensor, leak detection pump and PCV hoses. Intake Manifold Electrical Connectors And Vacuum Hose Connections - 2.0L Engine Manifold Absolute Pressure (MAP), Vapor Canister, And Brake Booster Hoses - 2.4L Engine 9. Disconnect intake air temperature electrical connector. Disconnect leak detection pump and PCV hoses. 10. Disconnect knock sensor electrical connector and disconnect wiring harness from tab located on the intake manifold. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1459 11. Remove transaxle to throttle body support bracket fasteners at the throttle body and loosen the fastener at the transaxle end. Tube Assembly - Typical 12. Remove EGR tube bolts at the valve and at the intake manifold. Remove tube from engine. Intake Manifold Tightening Sequence - 2.0L Engine Intake Manifold Tightening Sequence - 2.4L Engine 13. Remove the intake manifold support bracket. 14. Remove intake manifold fasteners and washer assemblies. Remove intake manifold. INSTALLATION Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1460 Intake Manifold Tightening Sequence - 2.4L Engine 1. Install new intake manifold gasket and tighten fasteners to 11.9 Nm (105 inch lbs.) in sequence shown. 2. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 inch lbs.). 3. Connect PCV and brake booster hoses. 4. Inspect quick connect fittings for damage, replace if necessary. Lubricate tube with clean engine oil. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position. 5. Install throttle body. Tighten fastener to 22 Nm (200 inch lbs.). Install transaxle to throttle body support bracket and tighten to 12 Nm (105 inch lbs.) at the throttle body first. Next tighten the bracket at the transaxle. 6. Connect manifold absolute pressure (MAP) and intake air temperature sensor wiring connectors. 7. Connect knock sensor electrical and starter relay connectors. Connect wiring harness to intake manifold tab. 8. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors. 9. Connect vacuum hoses to throttle body. 10. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever. 11. Loosely assemble the EGR tube onto valve and intake manifold finger tight. Tighten tube fasteners at the EGR valve first to 11 Nm (95 inch lbs.). Then, tighten the intake manifold side fasteners to 11 Nm (95 inch lbs.). 12. Connect negative cable to auxiliary jumper terminal. 13. With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1466 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Page 1467 Camshaft Oil Seal: Service and Repair REMOVAL 1. Remove front timing belt cover and timing belt. Camshaft Sprocket-Removal/Installation 2. Hold camshaft sprocket with Special Tool 6847 while removing center bolt. 3. Remove rear timing belt cover. Camshaft Oil Seal-Removal With C-4679-A 4. Remove camshaft seal using Special Tool C-4679-A. CAUTION: Do not nick shaft seal surface or seal bore INSTALLATION 1. Shaft seal surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Page 1468 Camshaft Seal-Installation 2. Install camshaft seal into cylinder head using Special Tool MD-998306 until flush with head. 3. Install rear timing belt cover. 4. Install camshaft sprocket. While holding sprocket with Special Tool 6847, tighten center bolt to 101 Nm (75 ft. lbs.). 5. Install timing belt and front covers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL Rear Crankshaft Oil Seal-Removal 1. Insert a 3/16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted. INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. NOTE: When installing seal, no lube on seal is needed. Rear Crankshaft Seal And Special Tool 6926-1 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1472 1. Place Special Tool 6926-1 on crankshaft. This is a pilot tool with a magnetic base. 2. Position seal over pilot tool. Make sure you can read the words THIS SIDE OUT on seal. Pilot tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation. CAUTION: If the seal is driven into the block past flush, this may cause an oil leak. Crankshaft Seal Special Tool 6926-2 Rear Crankshaft Seal-Installation 3. Drive the seal into the block using Special Tool 6926-2 and handle C-4171 until the tool bottoms out against the block. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures Technical Service Bulletin # 09-08-99 Date: 990917 Multi Layer Steel Head Gasket - Installation Procedures NUMBER: 09-08-99 GROUP: Engine DATE: Sep. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-05-98, DATED NOV. 6, 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 PART NUMBER REVISIONS AND MODEL ADDITIONS. SUBJECT: Multi-Layer Steel (MLS) Head Gasket Installation Procedures MODELS: **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - 2000 (JA) Cirrus/Stratus/Breeze 1996 - 2000 (JX) Sebring Convertible 1995-2000 (PL) Neon 1997 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC (NATURALLY ASPIRATED) OR 2.4L ENGINE. DISCUSSION: Multi-Layer Steel (MLS) head gaskets have been developed and released for use on the above models. The MLS gasket was released for production, as a running change, in the 1999 model year for all models except FJ. This new gasket provides superior sealing characteristics, but will require extra care in their installation where a composite gasket was previously in place. The following steps outline the proper installation of this MLS gasket. CAUTION: ALUMINUM ENGINE COMPONENTS ARE SUSCEPTIBLE TO METAL TRANSFER AND SURFACE DAMAGE WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING GASKET MATERIAL FROM ALUMINUM COMPONENTS. THE MLS GASKET CANNOT PROPERLY SEAL IF GOUGING OF SURFACES, METAL TRANSFER, OR COMPOSITE GASKET MATERIAL IS LEFT ON THE HEAD OR BLOCK SURFACES. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1477 PARTS REQUIRED: EQUIPMENT REQUIRED: 1 NPN Plastic/Wooden Scraper AR(1) 07528 2" 3M Roloc Bristle Disc White (For Aluminum Surfaces) AR(1) 07525 2" 3M Roloc Bristle Disc Yellow (For Aluminum/Cast Iron/Steel Surfaces) 1 05539 2" 3M Roloc Bristle Disc Arbor 1 NPN Drill Motor POLICY: Information Only. Repair Procedure This bulletin outlines the proper procedures for preparing head/block surfaces for MLS gasket installation. 1. Following service manual procedures, remove the head. 2. Remove as much of the loose composite gasket material with a plastic or wooden scraper. NOTE: PRIOR TO ADDITIONAL CLEANING, INSPECT THE COOLING PASSAGES OF THE HEAD. REPLACEMENT MAY BE NECESSARY IF EXCESSIVE PITTING OR EROSION HAS TAKEN PLACE THAT WILL COMPROMISE THE SEALING SURFACES AROUND THE COOLING PASSAGES. 3. Cover coolant and oil passages to the best of your ability and apply solvent or a commercially available gasket cleaner to the head/block surfaces. Allow the solvent to soften the remaining composite gasket material. 4. Using a plastic or wooden scraper, scrape the composite gasket residue from the surfaces. If necessary, apply additional solvent or gasket remover to ease removal. 5. If additional cleaning is needed, use a drill motor and 3M Roloc bristle disc p/n 07528 (white) to carefully remove the remaining gasket material from the head and block surfaces. NOTE: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1478 IF DIFFICULT TO REMOVE RESIDUE IS LEFT, THE YELLOW ROLOC BRISTLE DISK 3M P/N 07525 CAN BE USED. USE EXTREME CARE WHEN POWER CLEANING ALUMINUM SURFACES TO PREVENT METAL TRANSFER. 6. Inspect the sealing surfaces for any remaining composite gasket residue. Carefully remove any remaining material. 7. The head and block must be checked for flatness. Follow service manual procedures/specifications where applicable. 8. Spray both sides of the MLS gasket with a coat of MOPAR spray gasket sealant p/n 04318035. 9. Re-assemble the engine as outlined in the appropriate service manual. Pay particular attention to head bolt torque and torqueing procedures. All head bolts should be oiled prior to assembly. NOTE: THE 2.0L DOHC TORQUE AND TORQUING PROCEDURE HAS CHANGED WITH THE INSTALLATION OF A MLS GASKET. USE THE FOLLOWING PROCEDURES FOR THE 2.0L DOHC ONLY. 2.OL DOHC TORQUE PROCEDURE WITH MLS GASKET INSTALLATION NOTE: THE 4 SHORT BOLTS ARE PLACED IN THE CORNERS. A. Torque all center bolts to 34 Nm (25 Ft Lbs), Torque the 4 corner bolts to 27 Nm (20 Ft Lbs) see Fig 1 for torque sequence. B. Torque all center bolts to 68 Nm (50 Ft Lbs), Torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence. C. Re-torque all center bolts to 68 Nm (50 Ft Lbs), Re-torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence. D. Tighten all bolts in the specified sequence (Fig 1) an additional 90° (1/4 turn). 10. Make sure the cam sensor seal is replaced on all engine applications. NOTE: A NEW CAM SENSOR SEAL MUST BE INSTALLED DURING THE HEAD GASKET REPLACEMENT PROCEDURE. OIL SEEPAGE FROM THIS SEAL CAN BE MISINTERPRETED AS A HEAD GASKET LEAK. 11. Replace the engine oil and filter after performing these procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1479 Cylinder Head Gasket: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Crankshaft Damper-Removal 1. Using Special Tool 1026 and Insert 6827-A, remove crankshaft damper. 2. Remove timing belt. Crankshaft Sprocket-Removal 3. Remove crankshaft sprocket using Special Tool 6793 and insert C-4685-C2. CAUTION: Do not nick shaft seal surface or seal bore. Front Crankshaft Oil Seal-Removal Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1483 4. Using Tool 6771 to remove front crankshaft oil seal. Be careful not to damage the seal surface of cover. INSTALLATION Front Crankshaft Oil Seal-Installation 1. Install new seal by using Tool 6780. 2. Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. Crankshaft Sprocket-Installation 3. Install crankshaft sprocket. Using Special Tool 6792. 4. Install timing belt and timing belt covers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1484 Crankshaft Damper-Installation 5. Install crankshaft damper. Use thrust bearing/washer and 12M 1.75 x 150 mm bolt from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair REMOVAL 1. Remove camshafts. 2. Rotate crankshaft until piston is at TDC on compression. 3. With air hose attached to adapter tool installed in spark plug hole, apply 90 - 120 psi air pressure. Valve Spring-Removal/Installation 4 Using Special Tool MD-998772-A with adapter 6779 compress valve springs and remove valve locks. 5. Remove valve spring. 6. Remove valve stem seal by a using valve stem seal tool. INSTALLATION Valve Stem Seal/Valve Spring Seat 1. Install valve seal/valve spring seat assembly. Push the assembly down to seat it onto the valve guide. 2. Install valve spring and retainer, use Special Tool MD-998772-A with adapter 6779 to compress valve springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems. 3. Remove air hose and install spark plugs. 4. Install camshafts. 5. Install cylinder head cover. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations 2.4L Engine Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Carrier to Block Bolts ........................................................................................................................... .................................................... 54 Nm (40 ft. lbs.) Gear Cover Double Ended Fastener .................................................................................................................................................... 12 Nm (105 inch lbs.) Sprockets Bolts ..................................................................................................... .............................................................................. 28 Nm (250 inch lbs.) Chain Tensioner Bolts ....... .............................................................................................................................................................. .... 12 Nm (105 inch lbs.) Carrier Cover Fasteners .............................................................................. ......................................................................................... 12 Nm (105 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > Page 1496 Balance Shaft: Service and Repair BALANCE SHAFTS REMOVAL Refer to Timing Belt Cover and Timing Belt removal to repair balance shafts carrier assembly. Chain Cover, Guide And Tensioner 1. Remove chain cover, guide, and tensioner. 2. Remove gear cover retaining stud (double ended to also retain chain guide). Remove cover and balance shaft gears. 3. Remove balance shaft gear and chain sprocket retaining screws and crankshaft chain sprocket. Drive Chain And Sprockets Remove chain and sprocket assembly. Using two wide pry bars, work the sprocket back and forth until it is off the shaft. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > Page 1497 Gear Cover And Gears 4. Remove carrier gear cover and balance shafts. 5. Remove four carrier to crankcase attaching bolts to separate carrier from engine bedplate. BALANCE SHAFT CARRIER Balance Shaft(s)-Removal/Installation REMOVAL The following components will remain intact during carrier removal. Gear cover, gears, balance shafts and the rear cover. 1. Remove chain cover and driven balance shaft chain sprocket screw. 2. Loosen tensioner pivot and adjusting screws, move driven balance shaft inboard through driven chain sprocket. Sprocket will hang in lower chain loop. 3. Remove carrier to crankcase attaching bolts to remove carrier. BALANCE SHAFT INSTALLATION Balance shaft and carrier assembly installation is the reverse of the removal procedure. During installation crankshaft to balance shaft timing must be established. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > Page 1498 Balance Shaft(s)-Removal/Installation BALANCE SHAFT TIMING 1. With balance shafts installed in carrier position carrier on crankcase and install four attaching bolts and tighten to 54 Nm (40 ft. lbs.). Gear Timing 2. Turn balance shafts until both shaft key ways are up Parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After installation gear and balance shaft keyways must be up with gear timing marks meshed. 3. Install gear cover and tighten double ended stud/washer fastener to 12 Nm (105 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > Page 1499 Crankshaft Sprocket-Installation 4. Install crankshaft sprocket using Special Tool 6052. Balance Shaft Timing 5. Turn crankshaft until number one cylinder is at Top Dead Center (TDC). The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap. 6. Place chain over crankshaft sprocket so that the nickel plated link of the chain is over the number 1 cylinder timing mark on the crankshaft sprocket. 7. Place balance shaft sprocket into the timing chain so that the timing mark on the sprocket (yellow dot) mates with the (lower) nicked plated link on the chain 8. With balance shaft keyways pointing up (12 o'clock) slide the balance shaft sprocket onto the nose of the balance shaft. The balance shaft may Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications > Page 1500 have to be pushed in slightly to allow for clearance. NOTE: THE TIMING MARK ON THE SPROCKET THE (LOWER) NICKEL PLATED LINK, AND THE ARROW ON THE SIDE OF THE GEAR COVER SHOULD LINE UP WHEN THE BALANCE SHAFTS ARE TIMED CORRECTLY. 9. If the sprockets are timed correctly install the balance shaft bolts and tighten to 28 Nm (250 inch lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation. CHAIN TENSIONING 1. Install chain tensioner loosely assembled. 2. Position guide on double ended stud making sure tab on the guide fits into slot on the gear cover. Install and tighten nut/washer assembly to 12 Nm (105 inch lbs.). Chain Tension Adjustment 3. Place a shim 1 mm (0.039 inch) thick x 70 mm (2.75 inch) long or between tensioner and chain. Push tensioner and shim up against the chain.Apply firm pressure (5.5 to 6.6 lbs.) directly behind the adjustment slot to take up all slack. Chain must have shoe radius contact. 4. With the load applied, tighten top tensioner bolt first, then bottom pivot bolt. Tighten bolts to 12 Nm (105 inch lbs.). Remove shim. 5. Install carrier covers and tighten screws to 12 Nm (105 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 75 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications Timing Belt: Specifications On CA vehicles except 1997-2001 Sebring Convertible & 1998-2001 Cirrus & Stratus, replacement at 60,000 mile intervals is recommended but not required. On 1997-98 Sebring Convertible & 1998 Cirrus & Stratus models, replace at 105,000 mile intervals. On 1999-2001 Cirrus, Sebring Convertible & Stratus CA vehicles, replace every 105,000 miles. On 1999-2001 Cirrus, Sebring Convertible & Stratus non-CA vehicles, replace every 100,000 miles in normal service or every 99,000 miles in severe service. On 1996 Caravan, Town & Country & Voyager models, replace at 120,000 mile intervals. On 1997-98 Caravan & Voyager models, manufacturer does not recommend a specific maintenance interval. On 1999-2001 Caravan & Voyager models, replace every 90,000 miles. On 2000-01 Cirrus & Stratus non-CA vehicles, replace every 105,000 miles or 80 months in normal service, or every 99,000 miles in severe service. On 2000-01 Cirrus & Stratus CA vehicles, replace every 105,000 miles or 84 months. On all other models, replace at 100,000 mile intervals (if not previously replaced). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation Timing Belt: Service and Repair Timing Belt Removal and Installation 1. Raise vehicle on hoist. Remove right front wheel. 2. Remove right inner splash shield. 3. Remove accessory drive belts. 4. Remove crankshaft damper bolt, and remove damper. See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley 5. Remove lower timing belt cover fasteners and remove cover. 6. Lower vehicle and remove upper timing belt cover fasteners and remove cover. 7. Remove right engine mount and support bracket. CAUTION: When aligning crankshaft and camshaft timing marks always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt. 8. Before the removal of the timing belt, rotate crankshaft until the TDC mark on the oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1509 NOTE: The crankshaft sprocket TDC mark is located on the trailing edge of the sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause the camshaft timing marks to be misaligned. 9. Install 6 mm Allen wrench into belt tensioner. Before rotating the tensioner insert the long end of a 1/8" or 3 mm Allen wrench into the pin hole on the front of the tensioner. While rotating the tensioner counterclockwise push in lightly on the 1/8" or 3 mm Allen wrench, until it slides into the locking hole. 10. Remove timing belt. CAUTION: If timing belt was damaged due to incorrect tracking (alignment), the belt tensioner assembly must be replaced. INSTALLATION 1. Set crankshaft sprocket to Top Dead Center (TDC) by aligning the sprocket with the arrow on the oil pump housing. 2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket. CAUTION: Ensure that the arrows on both camshaft sprockets are facing up. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1510 3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner. 4. Move the exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. NOTE: A new tensioner is held in the wound position by a pull pin. 5. Remove the pull pin or Allen wrench from the belt tensioner. 6. Rotate crankshaft 2 revolutions and check the alignment of the timing marks. 7. Install right engine mount and support bracket. 8. Install upper timing belt cover bolts 4.5 Nm (40 inch lbs.). 9. Install the lower timing belt cover bolts 4.5 Nm (40 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1511 10. Install crankshaft damper. See: Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair 11. Install accessory drive belts. 12. Install right inner splash shield. 13. Install right front wheel. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1512 Timing Belt: Service and Repair Updated Mechanical Tensioner Installation Information INSTALLATION - TIMING BELT 1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. Fig. 102 Camshaft Sprocket Alignment 2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket. CAUTION: Ensure that the arrows on both camshaft sprockets are facing up. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1513 Fig. 103 Timing Belt Installation - Typical 3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner. 4. Move the exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1514 Fig. 104 Timing Belt Tension Adjustment 5. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley Rotate the top plate COUNTERCLOCKWISE . The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the allen wrench to prevent the top plate from moving, torque the tensioner lock nut to 25 Nm (220 in. lbs.). Setting notch and spring tang should remain aligned after lock nut is torqued. 6. Remove allen wrench and torque wrench. NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1515 Fig. 105 Crankshaft And Camshaft Timing 7. Once the timing belt has been installed and tensioner adjusted, rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position. Fig. 106 Timing Belt Tension Verification 8. Check if the spring tang is within the tolerance window. If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 5 through 7. 9. Continue with normal installation process. See: Timing Belt Removal and Installation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications Timing Belt Tensioner: Specifications Center Bolt ........................................................................................................................................... ............................................... 28 Nm (252 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Removal and Installation Timing Belt Tensioner: Service and Repair Removal and Installation REMOVAL 1. Remove timing belt. 2. Remove timing belt idler pulley. Camshaft Sprockets-Removal/Installation 3. Hold camshaft sprocket with Special Tool 6847 while removing bolt. Remove both cam sprockets. Rear Timing Belt Cover Fasteners 4. Remove rear timing belt cover fasteners and remove cover from engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Removal and Installation > Page 1521 Timing Belt Tensioner Assembly-Removal/Installation 5. Remove lower bolt attaching timing belt tensioner assembly to engine and remove tensioner as an assembly. INSTALLATION 1. Align timing belt tensioner assembly to engine and install lower mounting bolt but do not tighten. To properly align tensioner assembly-install one of the engine bracket mounting bolts (M10) 5 to 7 turns into the tensioner's upper mounting location. 2. Torque the tensioner's lower mounting bolt to 61 Nm (45 ft. lbs.). Remove the upper bolt used for tensioner alignment. 3. Install rear timing belt cover and fasteners. 4. Install timing belt idler pulley and torque mounting bolt to 61 Nm (45 ft. lbs.). 5. Install camshaft sprockets. Using Special Tool 6847 to hold sprockets, torque bolts to 101 Nm (75 ft. lbs.). 6. Install timing belt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Removal and Installation > Page 1522 Timing Belt Tensioner: Service and Repair Updated Mechanical Tensioner Installation Information INSTALLATION - TIMING BELT 1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. Fig. 102 Camshaft Sprocket Alignment 2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket. CAUTION: Ensure that the arrows on both camshaft sprockets are facing up. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Removal and Installation > Page 1523 Fig. 103 Timing Belt Installation - Typical 3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner. 4. Move the exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Removal and Installation > Page 1524 Fig. 104 Timing Belt Tension Adjustment 5. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley Rotate the top plate COUNTERCLOCKWISE . The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the allen wrench to prevent the top plate from moving, torque the tensioner lock nut to 25 Nm (220 in. lbs.). Setting notch and spring tang should remain aligned after lock nut is torqued. 6. Remove allen wrench and torque wrench. NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Service and Repair > Removal and Installation > Page 1525 Fig. 105 Crankshaft And Camshaft Timing 7. Once the timing belt has been installed and tensioner adjusted, rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position. Fig. 106 Timing Belt Tension Verification 8. Check if the spring tang is within the tolerance window. If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 5 through 7. 9. Continue with normal installation process. See: Timing Belt/Service and Repair/Timing Belt Removal and Installation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Outer to Inner Attaching Bolts M6 ....................................................................................................................................................... 4.5 Nm (40 inch lbs.) Inner Cover to Head/Oil Pump Bolts M6 ............................................................................................................................................ 12 Nm (105 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1529 Timing Cover: Service and Repair FRONT COVER Removal 1. Remove crankshaft damper. Front Timing Belt Covers 2. Remove front timing belt cover fasteners and remove covers. 3. Remove engine mount bracket. Installation 1. Install the engine mount bracket and front timing belt covers. 2. Install crankshaft damper. REAR COVER Removal 1. Remove front timing belt covers. 2. Remove Timing Belt. 3. Remove timing belt idler pulley. 4. Remove both camshaft sprockets. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1530 Rear Timing Belt Cover Fasteners 5. Remove rear timing belt fasteners and remove cover from engine. Installation 1. Install rear timing belt cover and fasteners. 2. Install timing belt idler. 3. Install camshaft sprocket and timing belt. 4. Install engine mount bracket. 5. Install front covers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fig. 1 Fuel Pressure Test Port--Typical Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 ................................................................................ .............................................................................................. 550 - 1,300 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 600 - 1,300 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1539 Idle Speed: Testing and Inspection Fig. 34 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. 34. Fig. 36 Orifice 6457 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. 36. 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 ............................................................................................................................. ........................................... 550 - 1,300 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 600 - 1,300 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. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1540 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1549 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cable Routing and Firing Order Firing Order Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable Resistance Cable #1 & #4 3,500 - 4,500 ohms Cable #2 & #3 2,950 - 4,100 ohms Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1560 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and 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. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1563 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 the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - 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, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE CABLE RESISTANCE #1 & #4 3,500 to 4,900 ohms #2 & #3 2,950 to 4,100 ohms 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 40,000 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 1566 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Resistance cables are identified by the words Electronic Suppression. SPARK PLUG CABLE SERVICE The cables insulate the spark plugs and covers the top of the spark plug tube Fig. 3. To remove the cables, lightly grasp the top of the cable. Rotate the insulator 90° and pull straight up. To replace the cables, disconnect the cable from the ignition coil. Ensure the #1 and #4 cables run under the #2 and #3 ignition coil towers. Keep #4 cable away from the oil fill cap. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................... 1.21-1.34 mm (0.048-0.53 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1570 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................... RC12YC5 Thread size ..................................................... ................................................................................................................................................. (14mm) 3/4 in. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1571 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1574 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 (L4-2.4L VIN X (1998)) 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 1575 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 (L4-2.4L VIN X (1998)) 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 1576 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 (L4-2.4L VIN X (1998)) 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 1577 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 (L4-2.4L VIN X (1998)) 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 1578 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 (L4-2.4L VIN X (1998)) 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 1579 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 (L4-2.4L VIN X (1998)) 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 1580 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 ^ 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 0.033 - 0.038 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. 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 (L4-2.4L VIN X (1998)) 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 1581 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1582 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap 0.048 to 0.053 in Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1583 Spark Plug: Service and Repair SPARK PLUG SERVICE Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 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. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: Special care should be used when installing spark plugs in the cylinder head spark plug wells. Re sure the plugs do not drop into the wells, damage to the electrodes can occur. 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SEE Testing and Inspection/Spark Plug Condition. Fig. 4 Setting Spark Plug Electrode Gap SPARK PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground electrode Fig. 4. SPARK PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. CAUTION: Over tightening can cause distortion and change spark plug gap. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. SPARK PLUG TUBES Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1584 The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. For engine information, SEE Engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure 170-225 psi Max. Variation Between Cylinders 25% Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1588 Compression Check: Testing and Inspection 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 adapter 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this engine has hydraulic lifters or adjusters which do not require nor have provisions for adjustment. See "Rocker Arm: Service and Repair" for further information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Mounting Bolts 105 in.lb Water Pump Inlet Tube to Block Bolts 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Description and Operation Water Pump: Description and Operation Water Pump The water has a diecast aluminum body and housing with a stamped steel impeller. The water pump bolts directly to the block. Cylinder block to water pump sealing is provided by a rubber O-ring. The water pump is driven by the timing belt. NOTE: The water pump on all models can be replaced without discharging the air conditioning system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Description and Operation > Page 1597 Water Pump: Description and Operation Construction 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Water Pump: Initial Inspection and Diagnostic Overview Replace water pump body assembly if it has any of these defects: 1. Cracks or damage on the body. 2. Coolant leaks from the shaft seal, evident by coolant traces on the pump body. 3. Loose or rough turning bearing. 4. Impeller rubs either the pump body or the engine block. 5. Impeller loose or damaged. 6. Sprocket or sprocket flange loose or clamaged. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1600 Water Pump: Component Tests and General Diagnostics 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. WARNING: DO NOT remove radiator cap if the cooling system is hot or under pressure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Testing and Inspection > Page 1601 Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts and power steering pump. 3. Drain cooling system. 4. Support engine from the bottom and remove right engine mount. 5. Remove right engine mount bracket. 6. Remove timing belt, camshaft sprockets, and rear timing belt cover. Water Pump 7. Remove water pump attaching screws to engine. INSTALLATION Water Pump Body 1. Install new O-ring gasket in water pump body O-ring groove. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak. 2. Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs.). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. 3. Rotate pump by hand to check for freedom of movement. 4. Install rear timing belt cover, camshaft sprockets, and timing belt. 5. Install right engine mount bracket and engine mount. 6. Fill cooling system. 7. Install power steering pump and accessory drive belts. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ............................................................ 8.5 L (9.0 qts) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1607 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information The cooling system is designed around the coolant. The coolant must accept heat from engine block metal and in the cylinder head area near the exhaust valves. Then coolant carries this heat to the radiator where the tube/fin assemblies of these components can give off the heat to the air. Mopar Antifreeze or the equivalent is recommended for optimum cooling performance and corrosion protection when mixed to a freeze point of -37° C (-35° F). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information > Page 1610 Coolant: Description and Operation Coolant Performance 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 the equivalent is recommended for optimum engine cooling and protection against corrosion when mixed 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 suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1611 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation Coolant Line/Hose: Description and Operation The inlet tube connects the water pump to the radiator and heater core. This tube is sealed by an O-ring and held in place by fasteners to the block. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Description and Operation > Page 1615 Coolant Line/Hose: Service and Repair REMOVAL 1. Drain cooling system. 2. Remove upper radiator hose to access the hose connections at the inlet tube. Water Pump Inlet Tube Hose Connections 3. Remove lower radiator hose and heater hose from the inlet tube. 4. Remove the 2 fasteners from that hold the inlet tube to the block. Water Pump Inlet Tube - Service 5. Rotate inlet tube while removing from the engine block. INSTALLATION 1. Inspect the O-ring for damage before installing the tube into the cylinder block. 2. Lube O-ring with coolant and install into the cylinder block opening. 3. Install 2 fasteners and tighten to 12 Nm (105 inch lbs.). 4. Connect lower radiator hose and heater hose to inlet tube. 5. Install upper radiator hose. 6. Fill cooling system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module Relay > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions Radiator Cooling Fan Control Module Relay: Technical Service Bulletins Cooling System - Manual Revisions NUMBER: 26-11-97G GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L/2.4L/2.5L SFI Engine Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the radiator fan control relay test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module Relay > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions > Page 1621 98 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Fan Motor to Shroud Fasteners ........................................................................................................... .................................................... 5 Nm (45 inch lbs.) Fan Module to Radiator Fasteners ........................................................................................................................................................... 7 Nm (65 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications > Page 1625 Radiator Cooling Fan Motor: Description and Operation Fan Module All models use electric motor driven, two speed cooling system fans. The fan modules include a motor support and shroud. The module is fastened to the radiator by bolts. NOTE: Attempts to reduce high temperature gauge reading by increasing engine speed, at the same vehicle speed, can increase high engine coolant temperature. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications > Page 1626 Radiator Cooling Fan Motor: Testing and Inspection Fan control is accomplished three ways. The fan runs when the air conditioning pressure reaches a set psi see charts below. 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 Powertrain Control Module (PCM). The PCM turns on the fan through a fan relay. On models equipped with automatic transmission, a transmission fluid thermistor may have some influences on fan operation. The (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 following information charts. Radiator Fan Operation - 2.4L Engine Radiator Fan Operation - 2.4L Engine Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications > Page 1627 Radiator Cooling Fan Motor: Service and Repair FAN SERVICE 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. Radiator Fan - Servicing 1. 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. Surface burr removal may be required to remove fan from motor shaft. Do not permit the fan blades to touch the bench. 2. To install fan on motor shaft, slide the fan over the shaft. Support motor and shaft while installing fan retaining clip. Fan Module Fan Module FAN SHROUD All have fan shrouds to improve fan air flow efficiency. The shroud supports the electric fan motor and fan. FAN MOTOR SERVICE 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. For wiring diagrams of fan motor systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay Power Distribution Center, Hi Speed Rad Fan Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay > Page 1632 Power Distribution Center, Lo Speed Radiator Fan Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay > Page 1633 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Radiator Fan Relay Power Distribution Center, Hi Speed Rad Fan Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Radiator Fan Relay > Page 1636 Power Distribution Center, Lo Speed Radiator Fan Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sensor Tightening Torque 20 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1641 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1642 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 14 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD bus to the Body Control Module (BCM) for the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies, the ECT sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor threads into the intake manifold next to the coolant fill neck/thermostat housing Fig. 14. New sensors have sealant applied to the threads. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 17 Engine Coolant Temperature Sensor To perform a complete test of this sensor and its circuitry, refer to DRB or scan tool and appropriate Computers and Control Systems/System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from coolant temperature sensor. 2. Connect one lead of a high input impedance (digital) volt-ohmmeter to one terminal of sensor. 3. Connect the other ohmmeter lead to remaining terminal of 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1645 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Temperature Gauge Indication 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 (L4-2.4L VIN X (1998)) 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 1646 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.2 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located at the rear of the cylinder head next to the camshaft position sensor Fig. 2. REMOVAL 1. With the engine cold, drain the cooling system until coolant level drops below sensor. Refer to Cooling System. 2. Disconnect ECT sensor electrical connector. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Tighten sensor to 27 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair 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 Heater-A/C Housing, Replacement. REMOVAL 1. Disconnect battery negative remote cable. Control Module 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair The heater hoses attach at the engine compartment cowl onto the heater core inlet/outlet and on the left side of the engine. The heater hoses are serviced separately of each other. The hoses can not be serviced with bulk roll heater hose. If it is necessary to replace a hose, use hose of the exact diameter and size and shape. The hoses are attached using spring tension clamps. REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Heater Hose Connection At Engine Heater Hose Connection At Heater Core 2. Using spring tension clamp pliers, remove clamps at each end of hose to be removed. 3. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Service and Repair Temperature Gauge: Service and Repair REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Service and Repair > Page 1657 Fuel Gauge And Temperature Gauge 4. Remove the fuel/temperature gauge attaching screws from the housing and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL CAUTION: Plastic tanks, while stronger then brass are subject to damage by impact, such as wrenches. Draincock - Typical 1. Turn the draincock 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 vehicle equipped with 2.5L engine, use a 3/8 inch drive extension 3" long, a 19 mm 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description and Operation Radiator Cap: Description and Operation The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97 - 124 kPa (14 - 18 psi). The cooling system will operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased radiator cooling capacity. Cooling System Pressure Cap There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting allowing coolant to return to radiator from coolant reserve system tank by vacuum, through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean the vent valve to ensure proper sealing when boiling point is reached. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve tank. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description and Operation > Page 1666 Radiator Cap: Description and Operation General Information Radiator Module 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. There is a vent valve in the center of the cap that allows a small coolant flow to the 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. 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 (L4-2.4L VIN X (1998)) 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 Cooling System Pressure Cap 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. 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1669 Radiator Cap: Component Tests and General Diagnostics Radiator Cap - Pressure Testing Pressure Testing Radiator Cap 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. 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 Cooling System Pressure Cap To Filler Neck 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1670 down, rotate it counter-clockwise to the first stop. Allow fluids to escape through the overflow tube. When the system stops pushing coolant and steam into the 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 (L4-2.4L VIN X (1998)) 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 counterclockwise 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. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clam. Always wear safety glasses when servicing constant tension clamps. CAUTION: 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. Hose Clamp Tool The hose clamps are removed by using Special Tool 6094 or equivalent constant tension clamp pliers to compress hose clamp. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. Spring type hose clamps are used in all applications. If replacement is necessary replace with the original Mopers equipment spring type clamp. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module Relay > Component Information > Technical Service Bulletins > Cooling System Manual Revisions Radiator Cooling Fan Control Module Relay: Technical Service Bulletins Cooling System - Manual Revisions NUMBER: 26-11-97G GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L/2.4L/2.5L SFI Engine Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the radiator fan control relay test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module Relay > Component Information > Technical Service Bulletins > Cooling System Manual Revisions > Page 1679 98 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay Power Distribution Center, Hi Speed Rad Fan Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay > Page 1684 Power Distribution Center, Lo Speed Radiator Fan Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > High Speed Fan Relay > Page 1685 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Radiator Fan Relay Power Distribution Center, Hi Speed Rad Fan Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > High Speed Radiator Fan Relay > Page 1688 Power Distribution Center, Lo Speed Radiator Fan Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sensor Tightening Torque 20 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1694 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1695 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 14 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD bus to the Body Control Module (BCM) for the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies, the ECT sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor threads into the intake manifold next to the coolant fill neck/thermostat housing Fig. 14. New sensors have sealant applied to the threads. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 17 Engine Coolant Temperature Sensor To perform a complete test of this sensor and its circuitry, refer to DRB or scan tool and appropriate Computers and Control Systems/System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from coolant temperature sensor. 2. Connect one lead of a high input impedance (digital) volt-ohmmeter to one terminal of sensor. 3. Connect the other ohmmeter lead to remaining terminal of 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1698 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Temperature Gauge Indication 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 (L4-2.4L VIN X (1998)) 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 1699 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.2 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located at the rear of the cylinder head next to the camshaft position sensor Fig. 2. REMOVAL 1. With the engine cold, drain the cooling system until coolant level drops below sensor. Refer to Cooling System. 2. Disconnect ECT sensor electrical connector. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Tighten sensor to 27 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Service and Repair Temperature Gauge: Service and Repair REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Service and Repair > Page 1703 Fuel Gauge And Temperature Gauge 4. Remove the fuel/temperature gauge attaching screws from the housing and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening ............................................................................................................................ ............................................................ 195 Degrees Thermostat Full Opening ..................................................................................................................... ........................................................... 216 Degrees Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > General Information Thermostat: Description and Operation General Information Thermostat And Engine Outlet Connector - 2.4L Engine The engine thermostat is located on the front of the engine (radiator side) in the thermostat housing/engine outlet connector. The thermostat has a air bleed located in the flange and a O-ring with a locating dimple incorporate on it. There is a relief in the cylinder head for locating the air bleed. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > General Information > Page 1709 Thermostat: Description and Operation The engine cooling thermostats are wax pellet driven, reverse poppet choke type. 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 to 93° C (192 to 199° F). They also automatically reach wide open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104° C (220° F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat. The thermostat is operated by a wax filled container (pellet) which is sealed. When heated coolant reaches 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 wax pellet will cause a thermostat to fail open. Do not attempt to free-up a stuck open thermostat. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 1710 Thermostat: Testing and Inspection The thermostat is operated by a wax filled container (pellet) which is sealed. When heated coolant reaches a predetermined temperature the wax pellet 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. 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, a diagnostic trouble code (DTC) will be set. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 1711 Thermostat: Service and Repair REMOVAL 1. Drain cooling system to the thermostat level or below. Thermostat And Engine Outlet Connector - 2.4L Engine 2. Remove coolant recovery system (CRS) hose and thermostat/engine outlet connector bolts. 3. Remove thermostat assembly, and clean sealing surfaces. INSTALLATION 1. Place the new thermostat assembly into the engine outlet connector. Align air bleed with notch on the cylinder head. 2. Install engine outlet connector onto cylinder head and tighten bolts to 12.5 Nm (110 inch lbs.). Connect the (CRS) hose. 3. Fill cooling system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Bolts ..................................................................................................................................................... ............................................ 12.5 Nm (110 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Mounting Bolts 105 in.lb Water Pump Inlet Tube to Block Bolts 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Description and Operation Water Pump: Description and Operation Water Pump The water has a diecast aluminum body and housing with a stamped steel impeller. The water pump bolts directly to the block. Cylinder block to water pump sealing is provided by a rubber O-ring. The water pump is driven by the timing belt. NOTE: The water pump on all models can be replaced without discharging the air conditioning system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Description and Operation > Page 1720 Water Pump: Description and Operation Construction 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Water Pump: Initial Inspection and Diagnostic Overview Replace water pump body assembly if it has any of these defects: 1. Cracks or damage on the body. 2. Coolant leaks from the shaft seal, evident by coolant traces on the pump body. 3. Loose or rough turning bearing. 4. Impeller rubs either the pump body or the engine block. 5. Impeller loose or damaged. 6. Sprocket or sprocket flange loose or clamaged. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1723 Water Pump: Component Tests and General Diagnostics 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. WARNING: DO NOT remove radiator cap if the cooling system is hot or under pressure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Testing and Inspection > Page 1724 Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts and power steering pump. 3. Drain cooling system. 4. Support engine from the bottom and remove right engine mount. 5. Remove right engine mount bracket. 6. Remove timing belt, camshaft sprockets, and rear timing belt cover. Water Pump 7. Remove water pump attaching screws to engine. INSTALLATION Water Pump Body 1. Install new O-ring gasket in water pump body O-ring groove. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak. 2. Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs.). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. 3. Rotate pump by hand to check for freedom of movement. 4. Install rear timing belt cover, camshaft sprockets, and timing belt. 5. Install right engine mount bracket and engine mount. 6. Fill cooling system. 7. Install power steering pump and accessory drive belts. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective Technical Service Bulletin # 7931 Date: 981201 Recall - Catalytic Converter Defective No. 7931 December, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7931 and # 7932 -- Catalytic Converter Models: 1998 Model Year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) Vehicles Built From March 1, 1998 Through March 21, 1998 (MDH 0301XX Through 0321XX) ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 The catalytic converter on about 1,500 of the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition, the catalytic converter must be replaced. IMPORTANT: This recall (# 7932) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7932 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system type "53" at the "ENTER FUNCTION" prompt, then type "ORD7931" (Federal emission vehicles) or "ORD7932" (California emission vehicles). Parts IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which catalytic converter is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate converter for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the following table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL. System Function 53 (involved dealers); or Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 1734 ^ Entering the VIN to DIAL System VIP Function (sales code information) along with the table (all dealers). Recall Completion Label Requirement For vehicles involved in Recall # 7932 there is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. Dealers are requested to order the required Authorized Modifications Label PN 04275086 as necessary to support scheduled repairs. Refer to the Service Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Copies of the owner notification letters are included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace catalytic converter 11793182 0.6 hours Add the cost of the catalytic converter plus applicable dealer allowance to your claim. Parts Return Removed catalytic converters must be returned to the Warranty Material Return Center. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Catalytic Converter 1. Raise vehicle on an appropriate hoist. 2. Loosen the exhaust clamp at catalytic converter to resonator slip joint. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 1735 3. Disconnect the downstream oxygen sensor electrical connector. 4. Using Miller Special Tool C-4907 remove the downstream oxygen sensor from the catalytic converter pipe. Mark and save the oxygen sensor for later reuse. (Figure 1). Caution: Upstream and downstream oxygen sensors are not interchangeable. Mark the sensors so that they can be transferred to their correct locations on the new catalyst. 5. For vehicles equipped with a 2.5L engine, disconnect the upstream oxygen sensor electrical connector. 6. Remove the catalytic converter to exhaust manifold fasteners. Save the fasteners and gasket for later reuse. 7. Disconnect the muffler ground strap, exhaust system hangers, and then lower the entire exhaust system to the floor. 8. For vehicles equipped with a 2.5L engine, use Miller Special Tool C-4907 to remove the upstream oxygen sensor from the catalytic converter. Mark and save the oxygen sensor for later reuse (Figure 1). 9. Separate the catalytic converter from the resonator and set it aside for ri3turn to the Warranty Material Return Center. 10. Connect the new catalytic converter assembly to the resonator. Tighten the catalytic converter to resonator clamp to 47 ft-lbs (64 N.m). 11. For vehicles equipped with a 2.5L engine, install the upstream oxygen sensor that was removed in step 8 using Miller Special Tool C-4907. Tighten the sensor to 20 ft lbs (28 N.m). Caution: Upstream and downstream oxygen sensors are not interchangeable. Be sure to install the upstream oxygen sensor in the correct location. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 1736 12. Raise the exhaust system into position and connect the exhaust system hangers. 13. Install the muffler ground strap. 14. Install the manifold-to-converter gasket saved in step 6. Position the catalyst flange onto manifold studs and tighten the exhaust manifold fasteners to 24 ft-lbs (32 N.m). 15. Install the downstream oxygen sensor that was removed in step 4 using Miller Special Tool C-4907. Tighten the sensor to 20 ft-lbs (28 N.m). 16. Connect the downstream oxygen sensor electrical connector. 17. For vehicles equipped with a 2.5L engine, connect the upstream oxygen sensor electrical connector. 18. Lower the vehicle. B. Install an Authorized Modifications Label For vehicles involved in Recall # 7932 located in California only: Type or print (with a ball point pen) the following information on an Authorized Modification Label (PN 4275086) and attach the label near the VECI label (Figure 2). C. Complete Proof of Correction Form For vehicles involved in Recall # 7932 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7931 and # 7932 -- Catalytic Converter ^ This service requirement applies only to 1998 model year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) vehicles built from March 1, 1998 through March 21, 1998 (MDH 0301XX through 0321XX) and equipped with a: ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 ^ The catalytic converter on the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition the catalytic converter must be replaced. ^ Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for Advance Service Information (ASI) # 98-17 is being canceled. Vehicles that have had the ASI repair performed have been removed from this recall. ^ For vehicles involved in Recall # 7932 located in California: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-O16-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Due to the small number of involved vehicles no parts will be distributed for this recall. 7931/7932 Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S CATALYTIC CONVERTER Dear Cirrus, Stratus or Breeze Owner: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 1737 Chrysler Corporation has determined that some 1998 Chrysler Cirrus, Dodge Stratus and Plymouth Breeze vehicles may be in violation of Federal Emissions Standards. The problem is... The catalytic converter on your Cirrus, Stratus or Breeze vehicle (identified on the enclosed form), may have been improperly welded, causing it to fail prematurely. This could result in hydrocarbon (HC), carbon monoxide (CO) and oxides of nitrogen (NOx) levels above the allowable limits which were established to protect the public health from the dangers of air pollution. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We are sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. 7931 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect Technical Service Bulletin # 7932 Date: 981201 Recall - Catalytic Converter Defect No. 7932 December, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7931 and # 7932 -- Catalytic Converter Models: 1998 Model Year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) Vehicles Built From March 1, 1998 Through March 21, 1998 (MDH 0301XX Through 0321XX) ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 The catalytic converter on about 1,500 of the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition, the catalytic converter must be replaced. IMPORTANT: This recall (# 7932) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7932 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system type "53" at the "ENTER FUNCTION" prompt, then type "ORD7931" (Federal emission vehicles) or "ORD7932" (California emission vehicles). Parts IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which catalytic converter is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate converter for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the following table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL. System Function 53 (involved dealers); or Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 1742 ^ Entering the VIN to DIAL System VIP Function (sales code information) along with the table (all dealers). Recall Completion Label Requirement For vehicles involved in Recall # 7932 there is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. Dealers are requested to order the required Authorized Modifications Label PN 04275086 as necessary to support scheduled repairs. Refer to the Service Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Copies of the owner notification letters are included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace catalytic converter 11793182 0.6 hours Add the cost of the catalytic converter plus applicable dealer allowance to your claim. Parts Return Removed catalytic converters must be returned to the Warranty Material Return Center. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Catalytic Converter 1. Raise vehicle on an appropriate hoist. 2. Loosen the exhaust clamp at catalytic converter to resonator slip joint. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 1743 3. Disconnect the downstream oxygen sensor electrical connector. 4. Using Miller Special Tool C-4907 remove the downstream oxygen sensor from the catalytic converter pipe. Mark and save the oxygen sensor for later reuse. (Figure 1). Caution: Upstream and downstream oxygen sensors are not interchangeable. Mark the sensors so that they can be transferred to their correct locations on the new catalyst. 5. For vehicles equipped with a 2.5L engine, disconnect the upstream oxygen sensor electrical connector. 6. Remove the catalytic converter to exhaust manifold fasteners. Save the fasteners and gasket for later reuse. 7. Disconnect the muffler ground strap, exhaust system hangers, and then lower the entire exhaust system to the floor. 8. For vehicles equipped with a 2.5L engine, use Miller Special Tool C-4907 to remove the upstream oxygen sensor from the catalytic converter. Mark and save the oxygen sensor for later reuse (Figure 1). 9. Separate the catalytic converter from the resonator and set it aside for ri3turn to the Warranty Material Return Center. 10. Connect the new catalytic converter assembly to the resonator. Tighten the catalytic converter to resonator clamp to 47 ft-lbs (64 N.m). 11. For vehicles equipped with a 2.5L engine, install the upstream oxygen sensor that was removed in step 8 using Miller Special Tool C-4907. Tighten the sensor to 20 ft lbs (28 N.m). Caution: Upstream and downstream oxygen sensors are not interchangeable. Be sure to install the upstream oxygen sensor in the correct location. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 1744 12. Raise the exhaust system into position and connect the exhaust system hangers. 13. Install the muffler ground strap. 14. Install the manifold-to-converter gasket saved in step 6. Position the catalyst flange onto manifold studs and tighten the exhaust manifold fasteners to 24 ft-lbs (32 N.m). 15. Install the downstream oxygen sensor that was removed in step 4 using Miller Special Tool C-4907. Tighten the sensor to 20 ft-lbs (28 N.m). 16. Connect the downstream oxygen sensor electrical connector. 17. For vehicles equipped with a 2.5L engine, connect the upstream oxygen sensor electrical connector. 18. Lower the vehicle. B. Install an Authorized Modifications Label For vehicles involved in Recall # 7932 located in California only: Type or print (with a ball point pen) the following information on an Authorized Modification Label (PN 4275086) and attach the label near the VECI label (Figure 2). C. Complete Proof of Correction Form For vehicles involved in Recall # 7932 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7931 and # 7932 -- Catalytic Converter ^ This service requirement applies only to 1998 model year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) vehicles built from March 1, 1998 through March 21, 1998 (MDH 0301XX through 0321XX) and equipped with a: ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 ^ The catalytic converter on the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition the catalytic converter must be replaced. ^ Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for Advance Service Information (ASI) # 98-17 is being canceled. Vehicles that have had the ASI repair performed have been removed from this recall. ^ For vehicles involved in Recall # 7932 located in California: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-O16-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Due to the small number of involved vehicles no parts will be distributed for this recall. 7931/7932 Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S CATALYTIC CONVERTER Dear Cirrus, Stratus, or Breeze Owner: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 1745 It has been determined that some 1998 Chrysler Cirrus, Dodge Stratus, and Plymouth Breeze vehicles may be in violation of California Emissions Standards. The problem is... The catalytic converter on your Cirrus, Stratus, or Breeze vehicle (identified on the enclosed form), may have been improperly welded, causing it to fail prematurely. This could result in hydrocarbon (HG), carbon monoxide (CO) and oxides of nitrogen (NOx) emission levels above the allowable limits, which were established to protect the public health from the dangers of air pollution. HG emissions consist of unburned fuel that is released into the atmosphere. HG in combination with NOx in the presence of sunlight, can cause the formation of ozone. CO emissions are formed by the incomplete combustion of fuel. These pollutants are the primary components of smog. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The service will take about one hour, but additional time may be required depending on how service work is scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. 7932 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective Technical Service Bulletin # 7931 Date: 981201 Recall - Catalytic Converter Defective No. 7931 December, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7931 and # 7932 -- Catalytic Converter Models: 1998 Model Year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) Vehicles Built From March 1, 1998 Through March 21, 1998 (MDH 0301XX Through 0321XX) ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 The catalytic converter on about 1,500 of the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition, the catalytic converter must be replaced. IMPORTANT: This recall (# 7932) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7932 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system type "53" at the "ENTER FUNCTION" prompt, then type "ORD7931" (Federal emission vehicles) or "ORD7932" (California emission vehicles). Parts IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which catalytic converter is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate converter for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the following table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL. System Function 53 (involved dealers); or Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 1751 ^ Entering the VIN to DIAL System VIP Function (sales code information) along with the table (all dealers). Recall Completion Label Requirement For vehicles involved in Recall # 7932 there is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. Dealers are requested to order the required Authorized Modifications Label PN 04275086 as necessary to support scheduled repairs. Refer to the Service Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Copies of the owner notification letters are included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace catalytic converter 11793182 0.6 hours Add the cost of the catalytic converter plus applicable dealer allowance to your claim. Parts Return Removed catalytic converters must be returned to the Warranty Material Return Center. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Catalytic Converter 1. Raise vehicle on an appropriate hoist. 2. Loosen the exhaust clamp at catalytic converter to resonator slip joint. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 1752 3. Disconnect the downstream oxygen sensor electrical connector. 4. Using Miller Special Tool C-4907 remove the downstream oxygen sensor from the catalytic converter pipe. Mark and save the oxygen sensor for later reuse. (Figure 1). Caution: Upstream and downstream oxygen sensors are not interchangeable. Mark the sensors so that they can be transferred to their correct locations on the new catalyst. 5. For vehicles equipped with a 2.5L engine, disconnect the upstream oxygen sensor electrical connector. 6. Remove the catalytic converter to exhaust manifold fasteners. Save the fasteners and gasket for later reuse. 7. Disconnect the muffler ground strap, exhaust system hangers, and then lower the entire exhaust system to the floor. 8. For vehicles equipped with a 2.5L engine, use Miller Special Tool C-4907 to remove the upstream oxygen sensor from the catalytic converter. Mark and save the oxygen sensor for later reuse (Figure 1). 9. Separate the catalytic converter from the resonator and set it aside for ri3turn to the Warranty Material Return Center. 10. Connect the new catalytic converter assembly to the resonator. Tighten the catalytic converter to resonator clamp to 47 ft-lbs (64 N.m). 11. For vehicles equipped with a 2.5L engine, install the upstream oxygen sensor that was removed in step 8 using Miller Special Tool C-4907. Tighten the sensor to 20 ft lbs (28 N.m). Caution: Upstream and downstream oxygen sensors are not interchangeable. Be sure to install the upstream oxygen sensor in the correct location. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 1753 12. Raise the exhaust system into position and connect the exhaust system hangers. 13. Install the muffler ground strap. 14. Install the manifold-to-converter gasket saved in step 6. Position the catalyst flange onto manifold studs and tighten the exhaust manifold fasteners to 24 ft-lbs (32 N.m). 15. Install the downstream oxygen sensor that was removed in step 4 using Miller Special Tool C-4907. Tighten the sensor to 20 ft-lbs (28 N.m). 16. Connect the downstream oxygen sensor electrical connector. 17. For vehicles equipped with a 2.5L engine, connect the upstream oxygen sensor electrical connector. 18. Lower the vehicle. B. Install an Authorized Modifications Label For vehicles involved in Recall # 7932 located in California only: Type or print (with a ball point pen) the following information on an Authorized Modification Label (PN 4275086) and attach the label near the VECI label (Figure 2). C. Complete Proof of Correction Form For vehicles involved in Recall # 7932 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7931 and # 7932 -- Catalytic Converter ^ This service requirement applies only to 1998 model year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) vehicles built from March 1, 1998 through March 21, 1998 (MDH 0301XX through 0321XX) and equipped with a: ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 ^ The catalytic converter on the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition the catalytic converter must be replaced. ^ Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for Advance Service Information (ASI) # 98-17 is being canceled. Vehicles that have had the ASI repair performed have been removed from this recall. ^ For vehicles involved in Recall # 7932 located in California: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-O16-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Due to the small number of involved vehicles no parts will be distributed for this recall. 7931/7932 Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S CATALYTIC CONVERTER Dear Cirrus, Stratus or Breeze Owner: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 1754 Chrysler Corporation has determined that some 1998 Chrysler Cirrus, Dodge Stratus and Plymouth Breeze vehicles may be in violation of Federal Emissions Standards. The problem is... The catalytic converter on your Cirrus, Stratus or Breeze vehicle (identified on the enclosed form), may have been improperly welded, causing it to fail prematurely. This could result in hydrocarbon (HC), carbon monoxide (CO) and oxides of nitrogen (NOx) levels above the allowable limits which were established to protect the public health from the dangers of air pollution. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We are sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. 7931 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect Technical Service Bulletin # 7932 Date: 981201 Recall - Catalytic Converter Defect No. 7932 December, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7931 and # 7932 -- Catalytic Converter Models: 1998 Model Year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) Vehicles Built From March 1, 1998 Through March 21, 1998 (MDH 0301XX Through 0321XX) ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 The catalytic converter on about 1,500 of the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition, the catalytic converter must be replaced. IMPORTANT: This recall (# 7932) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7932 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system type "53" at the "ENTER FUNCTION" prompt, then type "ORD7931" (Federal emission vehicles) or "ORD7932" (California emission vehicles). Parts IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which catalytic converter is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate converter for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the following table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL. System Function 53 (involved dealers); or Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 1759 ^ Entering the VIN to DIAL System VIP Function (sales code information) along with the table (all dealers). Recall Completion Label Requirement For vehicles involved in Recall # 7932 there is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. Dealers are requested to order the required Authorized Modifications Label PN 04275086 as necessary to support scheduled repairs. Refer to the Service Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Copies of the owner notification letters are included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace catalytic converter 11793182 0.6 hours Add the cost of the catalytic converter plus applicable dealer allowance to your claim. Parts Return Removed catalytic converters must be returned to the Warranty Material Return Center. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Catalytic Converter 1. Raise vehicle on an appropriate hoist. 2. Loosen the exhaust clamp at catalytic converter to resonator slip joint. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 1760 3. Disconnect the downstream oxygen sensor electrical connector. 4. Using Miller Special Tool C-4907 remove the downstream oxygen sensor from the catalytic converter pipe. Mark and save the oxygen sensor for later reuse. (Figure 1). Caution: Upstream and downstream oxygen sensors are not interchangeable. Mark the sensors so that they can be transferred to their correct locations on the new catalyst. 5. For vehicles equipped with a 2.5L engine, disconnect the upstream oxygen sensor electrical connector. 6. Remove the catalytic converter to exhaust manifold fasteners. Save the fasteners and gasket for later reuse. 7. Disconnect the muffler ground strap, exhaust system hangers, and then lower the entire exhaust system to the floor. 8. For vehicles equipped with a 2.5L engine, use Miller Special Tool C-4907 to remove the upstream oxygen sensor from the catalytic converter. Mark and save the oxygen sensor for later reuse (Figure 1). 9. Separate the catalytic converter from the resonator and set it aside for ri3turn to the Warranty Material Return Center. 10. Connect the new catalytic converter assembly to the resonator. Tighten the catalytic converter to resonator clamp to 47 ft-lbs (64 N.m). 11. For vehicles equipped with a 2.5L engine, install the upstream oxygen sensor that was removed in step 8 using Miller Special Tool C-4907. Tighten the sensor to 20 ft lbs (28 N.m). Caution: Upstream and downstream oxygen sensors are not interchangeable. Be sure to install the upstream oxygen sensor in the correct location. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 1761 12. Raise the exhaust system into position and connect the exhaust system hangers. 13. Install the muffler ground strap. 14. Install the manifold-to-converter gasket saved in step 6. Position the catalyst flange onto manifold studs and tighten the exhaust manifold fasteners to 24 ft-lbs (32 N.m). 15. Install the downstream oxygen sensor that was removed in step 4 using Miller Special Tool C-4907. Tighten the sensor to 20 ft-lbs (28 N.m). 16. Connect the downstream oxygen sensor electrical connector. 17. For vehicles equipped with a 2.5L engine, connect the upstream oxygen sensor electrical connector. 18. Lower the vehicle. B. Install an Authorized Modifications Label For vehicles involved in Recall # 7932 located in California only: Type or print (with a ball point pen) the following information on an Authorized Modification Label (PN 4275086) and attach the label near the VECI label (Figure 2). C. Complete Proof of Correction Form For vehicles involved in Recall # 7932 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7931 and # 7932 -- Catalytic Converter ^ This service requirement applies only to 1998 model year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) vehicles built from March 1, 1998 through March 21, 1998 (MDH 0301XX through 0321XX) and equipped with a: ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 ^ The catalytic converter on the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition the catalytic converter must be replaced. ^ Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for Advance Service Information (ASI) # 98-17 is being canceled. Vehicles that have had the ASI repair performed have been removed from this recall. ^ For vehicles involved in Recall # 7932 located in California: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-O16-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Due to the small number of involved vehicles no parts will be distributed for this recall. 7931/7932 Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S CATALYTIC CONVERTER Dear Cirrus, Stratus, or Breeze Owner: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 1762 It has been determined that some 1998 Chrysler Cirrus, Dodge Stratus, and Plymouth Breeze vehicles may be in violation of California Emissions Standards. The problem is... The catalytic converter on your Cirrus, Stratus, or Breeze vehicle (identified on the enclosed form), may have been improperly welded, causing it to fail prematurely. This could result in hydrocarbon (HG), carbon monoxide (CO) and oxides of nitrogen (NOx) emission levels above the allowable limits, which were established to protect the public health from the dangers of air pollution. HG emissions consist of unburned fuel that is released into the atmosphere. HG in combination with NOx in the presence of sunlight, can cause the formation of ozone. CO emissions are formed by the incomplete combustion of fuel. These pollutants are the primary components of smog. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The service will take about one hour, but additional time may be required depending on how service work is scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. 7932 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 1763 Fig. 1 Exhaust System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 1764 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter Operation > Page 1767 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1768 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Converter Servicing Catalytic Converter: Service and Repair Converter Servicing There is no regularly scheduled maintenance on the catalytic converter. If damaged, the converter must be replaced. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country (particularly vehicles built for States with strict emission requirements). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Converter Servicing > Page 1771 Catalytic Converter: Service and Repair Replacement 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Converter Servicing > Page 1772 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. Remove catalytic converter to exhaust manifold attaching fasteners. Remove catalytic converter from vehicle. 7. 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. Installation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Converter Servicing > Page 1773 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.). 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications Exhaust Crossover Pipe: Specifications Pipe Fasteners .................................................................................................................................... ................................................. 31 Nm (275 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications EGR Tube to Exhaust Manifold 97 in.lb Exhaust Manifold to Cylinder Head Bolts 200 in.lb Exhaust Manifold Heat Shield Bolts 105 in.lb Exhaust Manifold Flange Fasteners 250 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1780 Exhaust Manifold: Description and Operation The exhaust manifold is made of nodular cast iron for strength and high temperatures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. Remove exhaust pipe from manifold. It may be necessary to remove the entire exhaust system. Exhaust Manifold Heat Shield 2. Remove exhaust manifold heat shield. Exhaust Manifold 3. Remove 8 exhaust manifold retaining fasteners and remove exhaust manifold. INSTALLATION 1. Install new manifold gasket. DO NOT APPLY SEALER. 2. Position exhaust manifold in place. Tighten fasteners, starting at center and progressing outward in both directions to 23 Nm (200 inch lbs.) torque. Repeat this procedure until all fasteners are at specified torque. 3. Install exhaust manifold heat shield. 4. Attach exhaust pipe and tighten fasteners to 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1783 Exhaust Manifold: Service and Repair Cleaning and Inspection 1. Discard gasket and clean all surfaces of manifolds and cylinder head. 2. Test 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 as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Band Clamp Fastener .......................................................................................................................... ...................................................... 80 Nm (60 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Fasteners ............................................................................................................................................. ..................................................... 5 Nm (40 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1790 Heat Shield: Description and Operation Heat Shields 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. 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. 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations ETACS-ECU Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 1798 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 1799 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1802 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1803 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1804 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1805 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1806 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1807 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1808 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1809 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1810 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1811 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 (L4-2.4L VIN X (1998)) 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 1812 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 (L4-2.4L VIN X (1998)) 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 1813 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1814 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 (L4-2.4L VIN X (1998)) 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 1815 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1816 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 (L4-2.4L VIN X (1998)) 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 1817 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 (L4-2.4L VIN X (1998)) 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 1818 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 (L4-2.4L VIN X (1998)) 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 1819 Body Control Module: Connector Views BCM Connector BCM Connector BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1820 BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1821 Body Control Module: Electrical Diagrams Body Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1822 CCD Bus Wiring Diagrams Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1823 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1824 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1825 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1826 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1827 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1828 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1829 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1830 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1831 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1832 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Description Body Control Module: Description and Operation Description 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, the airbag control module (ACM), the smart key immobilized system (SKIM) and the antilock brake module (CAB). 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 - 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 - Power top inhibit (JX) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Description > Page 1835 Body Control Module: Description and Operation Introduction 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics 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. 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. Diagnostic Strategies VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis of the body system is done in six basic steps: Verification Of Complaint - Verification Of Any Related Symptoms - Symptom Analysis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Tests and General Diagnostics > Page 1838 - Problem Isolation - Repair Of Isolated Problem - Verification Of Proper Operation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1839 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 > Page 1843 Powertrain Control Module: 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 (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1846 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1847 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1848 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1849 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1850 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1851 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1852 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1853 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1854 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1855 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 (L4-2.4L VIN X (1998)) 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 1856 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 (L4-2.4L VIN X (1998)) 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 1857 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1858 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 (L4-2.4L VIN X (1998)) 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 1859 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1860 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 (L4-2.4L VIN X (1998)) 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 1861 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 (L4-2.4L VIN X (1998)) 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 1862 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 (L4-2.4L VIN X (1998)) 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 1863 Powertrain Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1864 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1867 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 (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) 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 > Service and Repair > Important Notes Powertrain Control Module: Service and Repair Important Notes IMPORTANT NOTE: If the Powertrain Control Module (PCM) has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Service and Repair > Important Notes > Page 1872 Powertrain Control Module: Service and Repair Procedure 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. NOTE: Use the DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and original mileage. If this step is not done a diagnostic trouble code may be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1876 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1877 Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1878 Automatic Shut Down (ASD) Relay: Description and Operation Fig 12 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 Power Distribution Center (PDC) -- located in the engine compartment. The inside top of the PDC cover has label showing relay and fuse identification. Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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 (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test > Page 1881 TEST 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations Fuel Pump Relay: Component Locations Power Distribution Center, Fuel Pump Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 1887 Power Distribution Center Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 1888 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1889 Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1890 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1891 Fuel Pump Relay: Testing and Inspection Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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. TEST Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1892 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1896 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1897 Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1898 Automatic Shut Down (ASD) Relay: Description and Operation Fig 12 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 Power Distribution Center (PDC) -- located in the engine compartment. The inside top of the PDC cover has label showing relay and fuse identification. Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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 (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test > Page 1901 TEST 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Left Front Of Impact Beam Below Grille, Battery Temperature Sensor, Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1907 Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1908 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1909 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1912 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1919 Camshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Camshaft Sensor Pick Up Bolts ..................................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1920 Camshaft Position Sensor: Locations Crank Shaft Position Sensor Camshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1921 Cam Shaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1922 Camshaft Position Sensor: Description and Operation Fig. 3 Camshaft Position Sensor 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. The sensor also acts as a thrust plate to control camshaft end play. Fig. 4 Target Magnet--Typical Fig. 5 Target Magnet Polarity Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1923 OPERATION The camshaft position sensor attaches to the rear of the cylinder head Fig. 4. A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity Fig. 5. The sensor input switches from high (5 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1924 Camshaft Position Sensor: Service and Repair Fig. 6 Camshaft Position Sensor Location Fig. 7 Target Magnet Removal Fig. 8 Target Magnet Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head Fig. 6. REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. 2. Remove air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove camshaft position sensor mounting screws. Remove sensor. 5. Loosen screw attaching target magnet to rear of camshaft Fig. 7. NOTE: The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1925 INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 4. Install air cleaner inlet tube and filtered air tube -- if applicable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sensor Tightening Torque 20 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1929 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1930 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 14 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD bus to the Body Control Module (BCM) for the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies, the ECT sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor threads into the intake manifold next to the coolant fill neck/thermostat housing Fig. 14. New sensors have sealant applied to the threads. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 17 Engine Coolant Temperature Sensor To perform a complete test of this sensor and its circuitry, refer to DRB or scan tool and appropriate Computers and Control Systems/System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from coolant temperature sensor. 2. Connect one lead of a high input impedance (digital) volt-ohmmeter to one terminal of sensor. 3. Connect the other ohmmeter lead to remaining terminal of 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1933 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Temperature Gauge Indication 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 (L4-2.4L VIN X (1998)) 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 1934 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.2 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located at the rear of the cylinder head next to the camshaft position sensor Fig. 2. REMOVAL 1. With the engine cold, drain the cooling system until coolant level drops below sensor. Refer to Cooling System. 2. Disconnect ECT sensor electrical connector. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Tighten sensor to 27 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1939 Crankshaft Position Sensor: Mechanical Specifications Sensor Screw Tightening Torque 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1940 Crankshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1941 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1942 Crankshaft Position Sensor: Description and Operation Fig 8 Timing Reference Notches Fig. 6 Timing Reference Notches Fig 9 Crankshaft Position Sensor OPERATION The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The second crankshaft counter-weight has machined into it two sets of four timing reference notches including a 60° signature notch Fig. 6. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1943 If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. The faster the engine is operating, the smaller the pulse-width on the oscilloscope. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69° Before Top Dead Center (BTDC). The second notch represents 49° BTDC. The third notch represents 29°. The last notch in each set represents 9° Before Top Dead Center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Fig. 8 Crankshaft Position Sensor The crankshaft position sensor attaches to the cowl side of the engine block. It is located between the main bearing cap/bed plate assembly and block behind the power steering pump Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1944 Crankshaft Position Sensor: Service and Repair Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter Fig. 9. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1951 Intake Manifold, Map Sensor, Throttle Body, Intake Air Tempt. Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1952 Intake Air Tempt. Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1953 Intake Air Temperature Sensor: Description and Operation Fig. 10 Intake Air Temperature Sensor And MAP Sensor The Intake Air Temperature (IAT) sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. The IAT sensor threads into the intake manifold. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 8 MAP Sensor And Intake Air Temperature Sensor To perform a complete test of this sensor and its circuitry; refer to DRB or Scan Tool and appropriate Computers and Control Systems/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. 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1956 Intake Air Temperature Sensor: Service and Repair Fig. 20 Intake Air Temperature Sensor And MAP Sensor The intake air temperature sensor threads into the intake manifold plenum Fig. 20. REMOVAL 1. Remove air inlet resonator. 2. Reaching through intake manifold from throttle body end, disconnect sensor connector. 3. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Attach electrical connector to sensor. 3. Install air inlet resonator. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor Torque 90 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1960 Knock Sensor: Locations Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 15 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 15. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increase, the knock sensor output voltage also increases. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 1963 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code NAME OF CODE: Knock Sensor Circuit WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The knock sensor circuit voltage (cavity 27) falls below a minimum value at idle or deceleration. The minimum value is from a look-up table internal to the Powertrain Control Module (PCM) and is based on engine RPM. The trouble code also sets if the sensor output is above 5.0 volts. THEORY OF OPERATION: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezo-electric discs, producing an electrical signal. The signal is used by PCM cavity 27 to adjust ignition timing to eliminate the knock condition. POSSIBLE CAUSES: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 1964 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. RMS voltage starts at about 20mVac -- at about 700 rpm - and increases to approximately 600 mVac -- at 5,000 rpm. If the output falls outside of this range a DTC will be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 1965 Knock Sensor: Service and Repair Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. REMOVAL 1. Disconnect electrical connector from knock sensor Fig. 12. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1970 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP sensor torque .............................................................................................................................. .......................................................... 2 Nm (20 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1971 Manifold Pressure/Vacuum Sensor: Locations MAP Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1972 Map Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1973 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 10 Intake Air Temperature Sensor And MAP Sensor OPERATION The Powertrain Control Module (PCM) supplies 5 volts to the Manifold Absolute Pressure (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. During cranking, before the engine starts running, 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 MAP sensor mounts to the intake manifold Fig. 10. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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 36 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 43. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1976 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 14 Temperature Sensor And MAP Sensor The MAP sensor attaches to the intake manifold plenum Fig. 14. REMOVAL 1. Disconnect the electrical connector from the 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 2 Nm (20 in. lbs) torque. 3. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Sensor Torque 20 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1982 Rear Bank Upstream Oxygen Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 1983 Down Stream Heated Oxygen Sensor, Catalytic Convertor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > 1/1 Upstream Oxygen Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > 1/1 > Page 1986 Downstream Oxygen Sensor Connector (Harness Side) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1987 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1988 Oxygen Sensor: Description and Operation Fig 11 Upstream Heated Oxygen Sensor 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 11). Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1989 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1990 Oxygen Sensor: Testing and Inspection 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: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig 90 Downstream Heated Oxygen Sensor Removal/Installation NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor. REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 90). 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 sensor electrical harness to clips along. body 3. Connect electrical connector to sensor. 4. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 1993 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig 88 Upstream Heated Oxygen Sensor Removal/Installation 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. 88). 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 1994 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 1999 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 (L4-2.4L VIN X (1998)) 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 2000 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2001 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2002 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2007 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2008 Fig. 35 Throttle Position Sensor And Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2009 Throttle Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2010 Throttle Position Sensor: Description and Operation Fig. 22 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 mounts to the side of the throttle body Fig. 22. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Testing 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2013 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2014 Throttle Position Sensor: Service and Repair Fig. 35 Throttle Position Sensor And Idle Air Control Motor THROTTLE POSITION SENSOR (TPS) SERVICE The throttle position sensor attaches to the side of the throttle body Fig. 35. 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 throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 36 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 36. - 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. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2023 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 (L4-2.4L VIN X (1998)) 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 2024 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 (L4-2.4L VIN X (1998)) 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 2025 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2031 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 (L4-2.4L VIN X (1998)) 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 2032 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2037 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 (L4-2.4L VIN X (1998)) 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 2038 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 (L4-2.4L VIN X (1998)) 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 2039 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2045 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 (L4-2.4L VIN X (1998)) 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 2046 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 (L4-2.4L VIN X (1998)) 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 2047 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2050 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2051 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2052 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 (L4-2.4L VIN X (1998)) 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 2053 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 (L4-2.4L VIN X (1998)) 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 2054 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions Vehicle Speed Sensor: Technical Service Bulletins Cooling System - Manual Revisions NUMBER: 26-11-97G GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L/2.4L/2.5L SFI Engine Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the radiator fan control relay test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions > Page 2059 98 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Manual Transmission Only Vehicle Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Manual Transmission Only > Page 2062 Vehicle Speed Sensor, Transaxle Extension Housing Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2065 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2066 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2067 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2068 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2069 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2070 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2071 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2072 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2073 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2074 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 (L4-2.4L VIN X (1998)) 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 2075 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 (L4-2.4L VIN X (1998)) 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 2076 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2077 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 (L4-2.4L VIN X (1998)) 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 2078 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2079 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 (L4-2.4L VIN X (1998)) 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 2080 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 (L4-2.4L VIN X (1998)) 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 2081 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 (L4-2.4L VIN X (1998)) 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 2082 Vehicle Speed Sensor: Connector Views Vehicle Speed Sensor Vehicle Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2083 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. Vehicle Speed And Distance The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. Vehicles with a 3 speed automatic or manual transmission have a vehicle speed sensor (VSS) mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Management/Computer and Control System for diagnosis and testing of this component 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2084 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2090 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2091 Fig. 35 Throttle Position Sensor And Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2092 Throttle Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2093 Throttle Position Sensor: Description and Operation Fig. 22 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 mounts to the side of the throttle body Fig. 22. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Testing 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2096 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2097 Throttle Position Sensor: Service and Repair Fig. 35 Throttle Position Sensor And Idle Air Control Motor THROTTLE POSITION SENSOR (TPS) SERVICE The throttle position sensor attaches to the side of the throttle body Fig. 35. 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 throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 36 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 36. - 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2105 Camshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Camshaft Sensor Pick Up Bolts ..................................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2106 Camshaft Position Sensor: Locations Crank Shaft Position Sensor Camshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2107 Cam Shaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2108 Camshaft Position Sensor: Description and Operation Fig. 3 Camshaft Position Sensor 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. The sensor also acts as a thrust plate to control camshaft end play. Fig. 4 Target Magnet--Typical Fig. 5 Target Magnet Polarity Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2109 OPERATION The camshaft position sensor attaches to the rear of the cylinder head Fig. 4. A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity Fig. 5. The sensor input switches from high (5 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2110 Camshaft Position Sensor: Service and Repair Fig. 6 Camshaft Position Sensor Location Fig. 7 Target Magnet Removal Fig. 8 Target Magnet Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head Fig. 6. REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. 2. Remove air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove camshaft position sensor mounting screws. Remove sensor. 5. Loosen screw attaching target magnet to rear of camshaft Fig. 7. NOTE: The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2111 INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 4. Install air cleaner inlet tube and filtered air tube -- if applicable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2116 Crankshaft Position Sensor: Mechanical Specifications Sensor Screw Tightening Torque 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2117 Crankshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2118 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2119 Crankshaft Position Sensor: Description and Operation Fig 8 Timing Reference Notches Fig. 6 Timing Reference Notches Fig 9 Crankshaft Position Sensor OPERATION The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The second crankshaft counter-weight has machined into it two sets of four timing reference notches including a 60° signature notch Fig. 6. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2120 If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. The faster the engine is operating, the smaller the pulse-width on the oscilloscope. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69° Before Top Dead Center (BTDC). The second notch represents 49° BTDC. The third notch represents 29°. The last notch in each set represents 9° Before Top Dead Center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Fig. 8 Crankshaft Position Sensor The crankshaft position sensor attaches to the cowl side of the engine block. It is located between the main bearing cap/bed plate assembly and block behind the power steering pump Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2121 Crankshaft Position Sensor: Service and Repair Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter Fig. 9. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2131 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2132 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 (L4-2.4L VIN X (1998)) 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 2133 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 (L4-2.4L VIN X (1998)) 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 2134 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 (L4-2.4L VIN X (1998)) 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 2135 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 (L4-2.4L VIN X (1998)) 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 2136 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 (L4-2.4L VIN X (1998)) 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 2137 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 (L4-2.4L VIN X (1998)) 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 2138 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 (L4-2.4L VIN X (1998)) 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 2139 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 (L4-2.4L VIN X (1998)) 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 2140 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 (L4-2.4L VIN X (1998)) 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 2141 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 (L4-2.4L VIN X (1998)) 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 2142 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2148 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2149 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 (L4-2.4L VIN X (1998)) 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 2150 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 (L4-2.4L VIN X (1998)) 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 2151 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 (L4-2.4L VIN X (1998)) 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 2152 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 (L4-2.4L VIN X (1998)) 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 2153 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 (L4-2.4L VIN X (1998)) 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 2154 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 (L4-2.4L VIN X (1998)) 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 2155 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 (L4-2.4L VIN X (1998)) 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 2156 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 (L4-2.4L VIN X (1998)) 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 2157 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 (L4-2.4L VIN X (1998)) 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 2158 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 (L4-2.4L VIN X (1998)) 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 2159 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2160 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 (L4-2.4L VIN X (1998)) 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 2161 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 (L4-2.4L VIN X (1998)) 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 2162 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor Torque 90 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2166 Knock Sensor: Locations Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 15 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 15. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increase, the knock sensor output voltage also increases. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 2169 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code NAME OF CODE: Knock Sensor Circuit WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The knock sensor circuit voltage (cavity 27) falls below a minimum value at idle or deceleration. The minimum value is from a look-up table internal to the Powertrain Control Module (PCM) and is based on engine RPM. The trouble code also sets if the sensor output is above 5.0 volts. THEORY OF OPERATION: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezo-electric discs, producing an electrical signal. The signal is used by PCM cavity 27 to adjust ignition timing to eliminate the knock condition. POSSIBLE CAUSES: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 2170 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. RMS voltage starts at about 20mVac -- at about 700 rpm - and increases to approximately 600 mVac -- at 5,000 rpm. If the output falls outside of this range a DTC will be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 2171 Knock Sensor: Service and Repair Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. REMOVAL 1. Disconnect electrical connector from knock sensor Fig. 12. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fig. 1 Fuel Pressure Test Port--Typical Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 ................................................................................ .............................................................................................. 550 - 1,300 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 600 - 1,300 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2180 Idle Speed: Testing and Inspection Fig. 34 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. 34. Fig. 36 Orifice 6457 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. 36. 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 ............................................................................................................................. ........................................... 550 - 1,300 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 600 - 1,300 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. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2181 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2190 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cable Routing and Firing Order Firing Order Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable Resistance Cable #1 & #4 3,500 - 4,500 ohms Cable #2 & #3 2,950 - 4,100 ohms Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2201 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and 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. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2204 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 the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - 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, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE CABLE RESISTANCE #1 & #4 3,500 to 4,900 ohms #2 & #3 2,950 to 4,100 ohms 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 40,000 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 2207 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Resistance cables are identified by the words Electronic Suppression. SPARK PLUG CABLE SERVICE The cables insulate the spark plugs and covers the top of the spark plug tube Fig. 3. To remove the cables, lightly grasp the top of the cable. Rotate the insulator 90° and pull straight up. To replace the cables, disconnect the cable from the ignition coil. Ensure the #1 and #4 cables run under the #2 and #3 ignition coil towers. Keep #4 cable away from the oil fill cap. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................... 1.21-1.34 mm (0.048-0.53 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2211 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................... RC12YC5 Thread size ..................................................... ................................................................................................................................................. (14mm) 3/4 in. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2212 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2215 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2216 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2217 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2218 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2219 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2220 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2221 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 ^ 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 0.033 - 0.038 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2222 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2223 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap 0.048 to 0.053 in Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2224 Spark Plug: Service and Repair SPARK PLUG SERVICE Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 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. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: Special care should be used when installing spark plugs in the cylinder head spark plug wells. Re sure the plugs do not drop into the wells, damage to the electrodes can occur. 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SEE Testing and Inspection/Spark Plug Condition. Fig. 4 Setting Spark Plug Electrode Gap SPARK PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground electrode Fig. 4. SPARK PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. CAUTION: Over tightening can cause distortion and change spark plug gap. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. SPARK PLUG TUBES Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2225 The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. For engine information, SEE Engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure 170-225 psi Max. Variation Between Cylinders 25% Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2229 Compression Check: Testing and Inspection 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 adapter 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this engine has hydraulic lifters or adjusters which do not require nor have provisions for adjustment. See "Rocker Arm: Service and Repair" for further information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay -- PCM Output > Page 2238 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay -- PCM Output > Page 2239 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2243 Intake Manifold, Map Sensor, Throttle Body, Intake Air Tempt. Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2244 Intake Air Tempt. Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2245 Intake Air Temperature Sensor: Description and Operation Fig. 10 Intake Air Temperature Sensor And MAP Sensor The Intake Air Temperature (IAT) sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. The IAT sensor threads into the intake manifold. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 8 MAP Sensor And Intake Air Temperature Sensor To perform a complete test of this sensor and its circuitry; refer to DRB or Scan Tool and appropriate Computers and Control Systems/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. 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2248 Intake Air Temperature Sensor: Service and Repair Fig. 20 Intake Air Temperature Sensor And MAP Sensor The intake air temperature sensor threads into the intake manifold plenum Fig. 20. REMOVAL 1. Remove air inlet resonator. 2. Reaching through intake manifold from throttle body end, disconnect sensor connector. 3. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Attach electrical connector to sensor. 3. Install air inlet resonator. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Left Front Of Impact Beam Below Grille, Battery Temperature Sensor, Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2252 Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2253 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2254 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2257 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations ETACS-ECU Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2262 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2263 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2273 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2274 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2275 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2276 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2277 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2278 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2279 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2280 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2281 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2282 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 Body Control Module: Connector Views BCM Connector BCM Connector BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2284 BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2285 Body Control Module: Electrical Diagrams Body Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 CCD Bus Wiring Diagrams Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Description Body Control Module: Description and Operation Description 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, the airbag control module (ACM), the smart key immobilized system (SKIM) and the antilock brake module (CAB). 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 - 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 - Power top inhibit (JX) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Description > Page 2299 Body Control Module: Description and Operation Introduction 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics 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. 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. Diagnostic Strategies VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis of the body system is done in six basic steps: Verification Of Complaint - Verification Of Any Related Symptoms - Symptom Analysis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2302 - Problem Isolation - Repair Of Isolated Problem - Verification Of Proper Operation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2303 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2307 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2314 Camshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Camshaft Sensor Pick Up Bolts ..................................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2315 Camshaft Position Sensor: Locations Crank Shaft Position Sensor Camshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2316 Cam Shaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2317 Camshaft Position Sensor: Description and Operation Fig. 3 Camshaft Position Sensor 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. The sensor also acts as a thrust plate to control camshaft end play. Fig. 4 Target Magnet--Typical Fig. 5 Target Magnet Polarity Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2318 OPERATION The camshaft position sensor attaches to the rear of the cylinder head Fig. 4. A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity Fig. 5. The sensor input switches from high (5 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2319 Camshaft Position Sensor: Service and Repair Fig. 6 Camshaft Position Sensor Location Fig. 7 Target Magnet Removal Fig. 8 Target Magnet Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head Fig. 6. REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. 2. Remove air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove camshaft position sensor mounting screws. Remove sensor. 5. Loosen screw attaching target magnet to rear of camshaft Fig. 7. NOTE: The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2320 INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 4. Install air cleaner inlet tube and filtered air tube -- if applicable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sensor Tightening Torque 20 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2324 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2325 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 14 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD bus to the Body Control Module (BCM) for the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies, the ECT sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor threads into the intake manifold next to the coolant fill neck/thermostat housing Fig. 14. New sensors have sealant applied to the threads. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 17 Engine Coolant Temperature Sensor To perform a complete test of this sensor and its circuitry, refer to DRB or scan tool and appropriate Computers and Control Systems/System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from coolant temperature sensor. 2. Connect one lead of a high input impedance (digital) volt-ohmmeter to one terminal of sensor. 3. Connect the other ohmmeter lead to remaining terminal of 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2328 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Temperature Gauge Indication 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2329 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.2 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located at the rear of the cylinder head next to the camshaft position sensor Fig. 2. REMOVAL 1. With the engine cold, drain the cooling system until coolant level drops below sensor. Refer to Cooling System. 2. Disconnect ECT sensor electrical connector. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Tighten sensor to 27 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2334 Crankshaft Position Sensor: Mechanical Specifications Sensor Screw Tightening Torque 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2335 Crankshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2336 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2337 Crankshaft Position Sensor: Description and Operation Fig 8 Timing Reference Notches Fig. 6 Timing Reference Notches Fig 9 Crankshaft Position Sensor OPERATION The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The second crankshaft counter-weight has machined into it two sets of four timing reference notches including a 60° signature notch Fig. 6. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2338 If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. The faster the engine is operating, the smaller the pulse-width on the oscilloscope. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69° Before Top Dead Center (BTDC). The second notch represents 49° BTDC. The third notch represents 29°. The last notch in each set represents 9° Before Top Dead Center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Fig. 8 Crankshaft Position Sensor The crankshaft position sensor attaches to the cowl side of the engine block. It is located between the main bearing cap/bed plate assembly and block behind the power steering pump Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2339 Crankshaft Position Sensor: Service and Repair Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter Fig. 9. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector Location Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2343 Data Link Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Testing and Inspection 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. NOTE: Electrical operation of the solenoid should be checked with the DRB scan tool before proceeding with the vacuum test. 1. Disconnect the rubber back-pressure hose from the fitting at the bottom of the transducer. 2. Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If vacuum falls off, the transducer diaphragm is leaking. 5. Replace the transducer and EGR valve assembly. Connect the rubber hose to the transducer and proceed to next step for further testing. 6. Reconnect the hose to the EGR valve. 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. A DTC will be set in the PCM that must be erased after testing is complete. 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. - To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present at valve. It must be high enough to hold the bleed valve in the transducer protion of the valve closed. - Have a helper momentarily -- for a second or two -- hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the vacuum gauge. Heavy gloves should be worn. CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. - 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. NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Testing and Inspection > Page 2347 EGR Backpressure Transducer: Service and Repair Fig. 1 EGR System 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 and transducer/solenoid attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. 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 lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lbs) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Specifications > Page 2351 Powertrain Control Module: 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 (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2356 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2357 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2358 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 Powertrain Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2372 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Component Description > Page 2375 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 (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Important Notes Powertrain Control Module: Service and Repair Important Notes IMPORTANT NOTE: If the Powertrain Control Module (PCM) has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Important Notes > Page 2380 Powertrain Control Module: Service and Repair Procedure 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. NOTE: Use the DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and original mileage. If this step is not done a diagnostic trouble code may be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Motor to throttle Body Bolts Torque 25 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2387 Idle Speed/Throttle Actuator - Electronic: Locations Idle Air Control Motor, Throttle Shield, Throttle Position Sensor Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2388 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2389 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig. 31 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). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2390 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 25 Throttle Position Sensor And Idle Air Control Motor The idle air control motor attaches to the side of the throttle body Fig. 25. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation Information Bus: Description and Operation 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor Torque 90 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2397 Knock Sensor: Locations Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 15 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 15. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increase, the knock sensor output voltage also increases. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 2400 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code NAME OF CODE: Knock Sensor Circuit WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The knock sensor circuit voltage (cavity 27) falls below a minimum value at idle or deceleration. The minimum value is from a look-up table internal to the Powertrain Control Module (PCM) and is based on engine RPM. The trouble code also sets if the sensor output is above 5.0 volts. THEORY OF OPERATION: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezo-electric discs, producing an electrical signal. The signal is used by PCM cavity 27 to adjust ignition timing to eliminate the knock condition. POSSIBLE CAUSES: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 2401 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. RMS voltage starts at about 20mVac -- at about 700 rpm - and increases to approximately 600 mVac -- at 5,000 rpm. If the output falls outside of this range a DTC will be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 2402 Knock Sensor: Service and Repair Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. REMOVAL 1. Disconnect electrical connector from knock sensor Fig. 12. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2406 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2407 Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2408 Automatic Shut Down (ASD) Relay: Description and Operation Fig 12 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 Power Distribution Center (PDC) -- located in the engine compartment. The inside top of the PDC cover has label showing relay and fuse identification. Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Fuel Pump & ASD Relay Test Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Fuel Pump & ASD Relay Test > Page 2411 TEST 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2416 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP sensor torque .............................................................................................................................. .......................................................... 2 Nm (20 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2417 Manifold Pressure/Vacuum Sensor: Locations MAP Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2418 Map Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2419 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 10 Intake Air Temperature Sensor And MAP Sensor OPERATION The Powertrain Control Module (PCM) supplies 5 volts to the Manifold Absolute Pressure (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. During cranking, before the engine starts running, 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 MAP sensor mounts to the intake manifold Fig. 10. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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 36 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 43. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2422 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 14 Temperature Sensor And MAP Sensor The MAP sensor attaches to the intake manifold plenum Fig. 14. REMOVAL 1. Disconnect the electrical connector from the 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 2 Nm (20 in. lbs) torque. 3. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Sensor Torque 20 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2428 Rear Bank Upstream Oxygen Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2429 Down Stream Heated Oxygen Sensor, Catalytic Convertor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > 1/1 Upstream Oxygen Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > 1/1 > Page 2432 Downstream Oxygen Sensor Connector (Harness Side) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2433 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2434 Oxygen Sensor: Description and Operation Fig 11 Upstream Heated Oxygen Sensor 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 11). Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2435 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2436 Oxygen Sensor: Testing and Inspection 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: Complete testing for this system or component can be found at the system level. See: Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig 90 Downstream Heated Oxygen Sensor Removal/Installation NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor. REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 90). 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 sensor electrical harness to clips along. body 3. Connect electrical connector to sensor. 4. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 2439 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig 88 Upstream Heated Oxygen Sensor Removal/Installation 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. 88). 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2440 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2445 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2446 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2447 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2448 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations ETACS-ECU Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2454 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2455 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2458 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2459 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2460 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2461 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2462 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2463 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2464 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2465 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2466 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2467 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 (L4-2.4L VIN X (1998)) 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 2468 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 (L4-2.4L VIN X (1998)) 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 2469 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2470 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 (L4-2.4L VIN X (1998)) 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 2471 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2472 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 (L4-2.4L VIN X (1998)) 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 2473 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 (L4-2.4L VIN X (1998)) 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 2474 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 (L4-2.4L VIN X (1998)) 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 2475 Body Control Module: Connector Views BCM Connector BCM Connector BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2476 BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2477 Body Control Module: Electrical Diagrams Body Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2478 CCD Bus Wiring Diagrams Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2479 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2480 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2481 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2482 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2483 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2484 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2485 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2486 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2487 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2488 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Description Body Control Module: Description and Operation Description 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, the airbag control module (ACM), the smart key immobilized system (SKIM) and the antilock brake module (CAB). 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 - 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 - Power top inhibit (JX) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Description > Page 2491 Body Control Module: Description and Operation Introduction 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics 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. 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. Diagnostic Strategies VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis of the body system is done in six basic steps: Verification Of Complaint - Verification Of Any Related Symptoms - Symptom Analysis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2494 - Problem Isolation - Repair Of Isolated Problem - Verification Of Proper Operation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2495 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 > Page 2499 Powertrain Control Module: 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 (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2502 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2503 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2504 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2505 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2506 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2507 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2508 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2509 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2510 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2511 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 (L4-2.4L VIN X (1998)) 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 2512 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 (L4-2.4L VIN X (1998)) 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 2513 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2514 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 (L4-2.4L VIN X (1998)) 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 2515 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2516 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 (L4-2.4L VIN X (1998)) 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 2517 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 (L4-2.4L VIN X (1998)) 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 2518 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 (L4-2.4L VIN X (1998)) 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 2519 Powertrain Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2520 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2523 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 (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Important Notes Powertrain Control Module: Service and Repair Important Notes IMPORTANT NOTE: If the Powertrain Control Module (PCM) has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Important Notes > Page 2528 Powertrain Control Module: Service and Repair Procedure 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. NOTE: Use the DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and original mileage. If this step is not done a diagnostic trouble code may be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2532 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2533 Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2534 Automatic Shut Down (ASD) Relay: Description and Operation Fig 12 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 Power Distribution Center (PDC) -- located in the engine compartment. The inside top of the PDC cover has label showing relay and fuse identification. Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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 (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test > Page 2537 TEST 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Left Front Of Impact Beam Below Grille, Battery Temperature Sensor, Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2542 Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2543 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2544 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2547 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2554 Camshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Camshaft Sensor Pick Up Bolts ..................................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2555 Camshaft Position Sensor: Locations Crank Shaft Position Sensor Camshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2556 Cam Shaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2557 Camshaft Position Sensor: Description and Operation Fig. 3 Camshaft Position Sensor 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. The sensor also acts as a thrust plate to control camshaft end play. Fig. 4 Target Magnet--Typical Fig. 5 Target Magnet Polarity Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2558 OPERATION The camshaft position sensor attaches to the rear of the cylinder head Fig. 4. A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity Fig. 5. The sensor input switches from high (5 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2559 Camshaft Position Sensor: Service and Repair Fig. 6 Camshaft Position Sensor Location Fig. 7 Target Magnet Removal Fig. 8 Target Magnet Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head Fig. 6. REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. 2. Remove air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove camshaft position sensor mounting screws. Remove sensor. 5. Loosen screw attaching target magnet to rear of camshaft Fig. 7. NOTE: The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2560 INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 4. Install air cleaner inlet tube and filtered air tube -- if applicable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sensor Tightening Torque 20 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2564 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2565 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 14 Engine Coolant Temperature Sensor OPERATION The Engine Coolant Temperature (ECT) sensor has one element. The element supplies coolant temperature signal to the PCM. The PCM supplies coolant temperature information on the CCD bus to the Body Control Module (BCM) for the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. As coolant temperature varies, the ECT sensor resistance changes resulting in a different input voltage to the PCM. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor threads into the intake manifold next to the coolant fill neck/thermostat housing Fig. 14. New sensors have sealant applied to the threads. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 17 Engine Coolant Temperature Sensor To perform a complete test of this sensor and its circuitry, refer to DRB or scan tool and appropriate Computers and Control Systems/System Diagnosis/Diagnostic Charts. To test the sensor only, refer to the following: 1. With the key off, disconnect wire harness connector from coolant temperature sensor. 2. Connect one lead of a high input impedance (digital) volt-ohmmeter to one terminal of sensor. 3. Connect the other ohmmeter lead to remaining terminal of 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2568 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Temperature Gauge Indication 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 (L4-2.4L VIN X (1998)) 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 2569 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.2 Engine Coolant Temperature Sensor The Engine Coolant Temperature (ECT) sensor is located at the rear of the cylinder head next to the camshaft position sensor Fig. 2. REMOVAL 1. With the engine cold, drain the cooling system until coolant level drops below sensor. Refer to Cooling System. 2. Disconnect ECT sensor electrical connector. 3. Remove ECT sensor. INSTALLATION 1. Install ECT sensor. Tighten sensor to 27 Nm (20 ft lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2574 Crankshaft Position Sensor: Mechanical Specifications Sensor Screw Tightening Torque 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2575 Crankshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2576 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2577 Crankshaft Position Sensor: Description and Operation Fig 8 Timing Reference Notches Fig. 6 Timing Reference Notches Fig 9 Crankshaft Position Sensor OPERATION The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The second crankshaft counter-weight has machined into it two sets of four timing reference notches including a 60° signature notch Fig. 6. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2578 If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. The faster the engine is operating, the smaller the pulse-width on the oscilloscope. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69° Before Top Dead Center (BTDC). The second notch represents 49° BTDC. The third notch represents 29°. The last notch in each set represents 9° Before Top Dead Center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Fig. 8 Crankshaft Position Sensor The crankshaft position sensor attaches to the cowl side of the engine block. It is located between the main bearing cap/bed plate assembly and block behind the power steering pump Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2579 Crankshaft Position Sensor: Service and Repair Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter Fig. 9. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2586 Intake Manifold, Map Sensor, Throttle Body, Intake Air Tempt. Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2587 Intake Air Tempt. Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2588 Intake Air Temperature Sensor: Description and Operation Fig. 10 Intake Air Temperature Sensor And MAP Sensor The Intake Air Temperature (IAT) sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. The IAT sensor threads into the intake manifold. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 8 MAP Sensor And Intake Air Temperature Sensor To perform a complete test of this sensor and its circuitry; refer to DRB or Scan Tool and appropriate Computers and Control Systems/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. 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 Diagrams/Electrical for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2591 Intake Air Temperature Sensor: Service and Repair Fig. 20 Intake Air Temperature Sensor And MAP Sensor The intake air temperature sensor threads into the intake manifold plenum Fig. 20. REMOVAL 1. Remove air inlet resonator. 2. Reaching through intake manifold from throttle body end, disconnect sensor connector. 3. Remove sensor. INSTALLATION 1. Install sensor. Tighten sensor to 28 Nm (20 ft. lbs.) torque. 2. Attach electrical connector to sensor. 3. Install air inlet resonator. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor Torque 90 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2595 Knock Sensor: Locations Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 15 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 15. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increase, the knock sensor output voltage also increases. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 2598 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code NAME OF CODE: Knock Sensor Circuit WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The knock sensor circuit voltage (cavity 27) falls below a minimum value at idle or deceleration. The minimum value is from a look-up table internal to the Powertrain Control Module (PCM) and is based on engine RPM. The trouble code also sets if the sensor output is above 5.0 volts. THEORY OF OPERATION: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezo-electric discs, producing an electrical signal. The signal is used by PCM cavity 27 to adjust ignition timing to eliminate the knock condition. POSSIBLE CAUSES: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 2599 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. RMS voltage starts at about 20mVac -- at about 700 rpm - and increases to approximately 600 mVac -- at 5,000 rpm. If the output falls outside of this range a DTC will be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 2600 Knock Sensor: Service and Repair Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. REMOVAL 1. Disconnect electrical connector from knock sensor Fig. 12. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2605 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP sensor torque .............................................................................................................................. .......................................................... 2 Nm (20 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2606 Manifold Pressure/Vacuum Sensor: Locations MAP Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2607 Map Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2608 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 10 Intake Air Temperature Sensor And MAP Sensor OPERATION The Powertrain Control Module (PCM) supplies 5 volts to the Manifold Absolute Pressure (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. During cranking, before the engine starts running, 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 MAP sensor mounts to the intake manifold Fig. 10. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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 36 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 43. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2611 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 14 Temperature Sensor And MAP Sensor The MAP sensor attaches to the intake manifold plenum Fig. 14. REMOVAL 1. Disconnect the electrical connector from the 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 2 Nm (20 in. lbs) torque. 3. Attach electrical connector to sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Sensor Torque 20 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2617 Rear Bank Upstream Oxygen Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2618 Down Stream Heated Oxygen Sensor, Catalytic Convertor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > 1/1 Upstream Oxygen Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > 1/1 > Page 2621 Downstream Oxygen Sensor Connector (Harness Side) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2622 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2623 Oxygen Sensor: Description and Operation Fig 11 Upstream Heated Oxygen Sensor 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 11). Fig 13 Downstream Heated Oxygen Sensor 1/2 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2624 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2625 Oxygen Sensor: Testing and Inspection 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: Complete testing for this system or component can be found at the system level. See: Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig 90 Downstream Heated Oxygen Sensor Removal/Installation NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor. REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 90). 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 sensor electrical harness to clips along. body 3. Connect electrical connector to sensor. 4. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 2628 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig 88 Upstream Heated Oxygen Sensor Removal/Installation 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. 88). 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2629 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2634 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2635 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2636 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2637 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2642 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2643 Fig. 35 Throttle Position Sensor And Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2644 Throttle Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2645 Throttle Position Sensor: Description and Operation Fig. 22 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 mounts to the side of the throttle body Fig. 22. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Testing 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2648 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2649 Throttle Position Sensor: Service and Repair Fig. 35 Throttle Position Sensor And Idle Air Control Motor THROTTLE POSITION SENSOR (TPS) SERVICE The throttle position sensor attaches to the side of the throttle body Fig. 35. 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 throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 36 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 36. - 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. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2658 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 (L4-2.4L VIN X (1998)) 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 2659 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 (L4-2.4L VIN X (1998)) 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 2660 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2666 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 (L4-2.4L VIN X (1998)) 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 2667 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2672 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 (L4-2.4L VIN X (1998)) 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 2673 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 (L4-2.4L VIN X (1998)) 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 2674 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2680 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 (L4-2.4L VIN X (1998)) 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 2681 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 (L4-2.4L VIN X (1998)) 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 2682 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2685 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2686 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2687 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 (L4-2.4L VIN X (1998)) 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 2688 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 (L4-2.4L VIN X (1998)) 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 2689 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions Vehicle Speed Sensor: Technical Service Bulletins Cooling System - Manual Revisions NUMBER: 26-11-97G GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L/2.4L/2.5L SFI Engine Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the radiator fan control relay test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions > Page 2694 98 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Manual Transmission Only Vehicle Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Manual Transmission Only > Page 2697 Vehicle Speed Sensor, Transaxle Extension Housing Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2700 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2701 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2702 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2703 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2704 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2705 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2706 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2707 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2708 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2709 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 (L4-2.4L VIN X (1998)) 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 2710 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 (L4-2.4L VIN X (1998)) 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 2711 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2712 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 (L4-2.4L VIN X (1998)) 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 2713 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 2714 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 (L4-2.4L VIN X (1998)) 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 2715 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 (L4-2.4L VIN X (1998)) 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 2716 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 (L4-2.4L VIN X (1998)) 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 2717 Vehicle Speed Sensor: Connector Views Vehicle Speed Sensor Vehicle Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2718 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. Vehicle Speed And Distance The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. Vehicles with a 3 speed automatic or manual transmission have a vehicle speed sensor (VSS) mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Management/Computer and Control System for diagnosis and testing of this component 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2719 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2727 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2728 Fig. 35 Throttle Position Sensor And Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2729 Throttle Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2730 Throttle Position Sensor: Description and Operation Fig. 22 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 mounts to the side of the throttle body Fig. 22. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Testing 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2733 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2734 Throttle Position Sensor: Service and Repair Fig. 35 Throttle Position Sensor And Idle Air Control Motor THROTTLE POSITION SENSOR (TPS) SERVICE The throttle position sensor attaches to the side of the throttle body Fig. 35. 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 throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 36 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 36. - 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. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2746 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 (L4-2.4L VIN X (1998)) 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 2747 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 (L4-2.4L VIN X (1998)) 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 2748 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2754 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 (L4-2.4L VIN X (1998)) 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 2755 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2760 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 (L4-2.4L VIN X (1998)) 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 2761 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 (L4-2.4L VIN X (1998)) 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 2762 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2768 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 (L4-2.4L VIN X (1998)) 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 2769 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2770 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 2773 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2774 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2775 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2776 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2777 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions Vehicle Speed Sensor: Technical Service Bulletins Cooling System - Manual Revisions NUMBER: 26-11-97G GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L/2.4L/2.5L SFI Engine Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the radiator fan control relay test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Cooling System - Manual Revisions > Page 2782 98 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Manual Transmission Only Vehicle Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Manual Transmission Only > Page 2785 Vehicle Speed Sensor, Transaxle Extension Housing Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2788 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2789 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2790 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2791 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2792 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2793 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2794 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2795 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2796 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2797 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2798 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2799 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2800 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2801 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2802 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2803 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2804 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2805 Vehicle Speed Sensor: Connector Views Vehicle Speed Sensor Vehicle Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2806 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. Vehicle Speed And Distance The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. Vehicles with a 3 speed automatic or manual transmission have a vehicle speed sensor (VSS) mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Management/Computer and Control System for diagnosis and testing of this component 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2807 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications > Page 2811 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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). 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 the PCM. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation > Page 2814 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective Technical Service Bulletin # 7931 Date: 981201 Recall - Catalytic Converter Defective No. 7931 December, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7931 and # 7932 -- Catalytic Converter Models: 1998 Model Year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) Vehicles Built From March 1, 1998 Through March 21, 1998 (MDH 0301XX Through 0321XX) ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 The catalytic converter on about 1,500 of the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition, the catalytic converter must be replaced. IMPORTANT: This recall (# 7932) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7932 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system type "53" at the "ENTER FUNCTION" prompt, then type "ORD7931" (Federal emission vehicles) or "ORD7932" (California emission vehicles). Parts IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which catalytic converter is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate converter for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the following table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL. System Function 53 (involved dealers); or Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 2824 ^ Entering the VIN to DIAL System VIP Function (sales code information) along with the table (all dealers). Recall Completion Label Requirement For vehicles involved in Recall # 7932 there is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. Dealers are requested to order the required Authorized Modifications Label PN 04275086 as necessary to support scheduled repairs. Refer to the Service Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Copies of the owner notification letters are included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace catalytic converter 11793182 0.6 hours Add the cost of the catalytic converter plus applicable dealer allowance to your claim. Parts Return Removed catalytic converters must be returned to the Warranty Material Return Center. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Catalytic Converter 1. Raise vehicle on an appropriate hoist. 2. Loosen the exhaust clamp at catalytic converter to resonator slip joint. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 2825 3. Disconnect the downstream oxygen sensor electrical connector. 4. Using Miller Special Tool C-4907 remove the downstream oxygen sensor from the catalytic converter pipe. Mark and save the oxygen sensor for later reuse. (Figure 1). Caution: Upstream and downstream oxygen sensors are not interchangeable. Mark the sensors so that they can be transferred to their correct locations on the new catalyst. 5. For vehicles equipped with a 2.5L engine, disconnect the upstream oxygen sensor electrical connector. 6. Remove the catalytic converter to exhaust manifold fasteners. Save the fasteners and gasket for later reuse. 7. Disconnect the muffler ground strap, exhaust system hangers, and then lower the entire exhaust system to the floor. 8. For vehicles equipped with a 2.5L engine, use Miller Special Tool C-4907 to remove the upstream oxygen sensor from the catalytic converter. Mark and save the oxygen sensor for later reuse (Figure 1). 9. Separate the catalytic converter from the resonator and set it aside for ri3turn to the Warranty Material Return Center. 10. Connect the new catalytic converter assembly to the resonator. Tighten the catalytic converter to resonator clamp to 47 ft-lbs (64 N.m). 11. For vehicles equipped with a 2.5L engine, install the upstream oxygen sensor that was removed in step 8 using Miller Special Tool C-4907. Tighten the sensor to 20 ft lbs (28 N.m). Caution: Upstream and downstream oxygen sensors are not interchangeable. Be sure to install the upstream oxygen sensor in the correct location. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 2826 12. Raise the exhaust system into position and connect the exhaust system hangers. 13. Install the muffler ground strap. 14. Install the manifold-to-converter gasket saved in step 6. Position the catalyst flange onto manifold studs and tighten the exhaust manifold fasteners to 24 ft-lbs (32 N.m). 15. Install the downstream oxygen sensor that was removed in step 4 using Miller Special Tool C-4907. Tighten the sensor to 20 ft-lbs (28 N.m). 16. Connect the downstream oxygen sensor electrical connector. 17. For vehicles equipped with a 2.5L engine, connect the upstream oxygen sensor electrical connector. 18. Lower the vehicle. B. Install an Authorized Modifications Label For vehicles involved in Recall # 7932 located in California only: Type or print (with a ball point pen) the following information on an Authorized Modification Label (PN 4275086) and attach the label near the VECI label (Figure 2). C. Complete Proof of Correction Form For vehicles involved in Recall # 7932 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7931 and # 7932 -- Catalytic Converter ^ This service requirement applies only to 1998 model year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) vehicles built from March 1, 1998 through March 21, 1998 (MDH 0301XX through 0321XX) and equipped with a: ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 ^ The catalytic converter on the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition the catalytic converter must be replaced. ^ Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for Advance Service Information (ASI) # 98-17 is being canceled. Vehicles that have had the ASI repair performed have been removed from this recall. ^ For vehicles involved in Recall # 7932 located in California: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-O16-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Due to the small number of involved vehicles no parts will be distributed for this recall. 7931/7932 Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S CATALYTIC CONVERTER Dear Cirrus, Stratus or Breeze Owner: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 2827 Chrysler Corporation has determined that some 1998 Chrysler Cirrus, Dodge Stratus and Plymouth Breeze vehicles may be in violation of Federal Emissions Standards. The problem is... The catalytic converter on your Cirrus, Stratus or Breeze vehicle (identified on the enclosed form), may have been improperly welded, causing it to fail prematurely. This could result in hydrocarbon (HC), carbon monoxide (CO) and oxides of nitrogen (NOx) levels above the allowable limits which were established to protect the public health from the dangers of air pollution. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We are sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. 7931 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect Technical Service Bulletin # 7932 Date: 981201 Recall - Catalytic Converter Defect No. 7932 December, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7931 and # 7932 -- Catalytic Converter Models: 1998 Model Year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) Vehicles Built From March 1, 1998 Through March 21, 1998 (MDH 0301XX Through 0321XX) ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 The catalytic converter on about 1,500 of the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition, the catalytic converter must be replaced. IMPORTANT: This recall (# 7932) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7932 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system type "53" at the "ENTER FUNCTION" prompt, then type "ORD7931" (Federal emission vehicles) or "ORD7932" (California emission vehicles). Parts IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which catalytic converter is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate converter for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the following table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL. System Function 53 (involved dealers); or Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 2832 ^ Entering the VIN to DIAL System VIP Function (sales code information) along with the table (all dealers). Recall Completion Label Requirement For vehicles involved in Recall # 7932 there is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. Dealers are requested to order the required Authorized Modifications Label PN 04275086 as necessary to support scheduled repairs. Refer to the Service Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Copies of the owner notification letters are included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace catalytic converter 11793182 0.6 hours Add the cost of the catalytic converter plus applicable dealer allowance to your claim. Parts Return Removed catalytic converters must be returned to the Warranty Material Return Center. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Catalytic Converter 1. Raise vehicle on an appropriate hoist. 2. Loosen the exhaust clamp at catalytic converter to resonator slip joint. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 2833 3. Disconnect the downstream oxygen sensor electrical connector. 4. Using Miller Special Tool C-4907 remove the downstream oxygen sensor from the catalytic converter pipe. Mark and save the oxygen sensor for later reuse. (Figure 1). Caution: Upstream and downstream oxygen sensors are not interchangeable. Mark the sensors so that they can be transferred to their correct locations on the new catalyst. 5. For vehicles equipped with a 2.5L engine, disconnect the upstream oxygen sensor electrical connector. 6. Remove the catalytic converter to exhaust manifold fasteners. Save the fasteners and gasket for later reuse. 7. Disconnect the muffler ground strap, exhaust system hangers, and then lower the entire exhaust system to the floor. 8. For vehicles equipped with a 2.5L engine, use Miller Special Tool C-4907 to remove the upstream oxygen sensor from the catalytic converter. Mark and save the oxygen sensor for later reuse (Figure 1). 9. Separate the catalytic converter from the resonator and set it aside for ri3turn to the Warranty Material Return Center. 10. Connect the new catalytic converter assembly to the resonator. Tighten the catalytic converter to resonator clamp to 47 ft-lbs (64 N.m). 11. For vehicles equipped with a 2.5L engine, install the upstream oxygen sensor that was removed in step 8 using Miller Special Tool C-4907. Tighten the sensor to 20 ft lbs (28 N.m). Caution: Upstream and downstream oxygen sensors are not interchangeable. Be sure to install the upstream oxygen sensor in the correct location. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 2834 12. Raise the exhaust system into position and connect the exhaust system hangers. 13. Install the muffler ground strap. 14. Install the manifold-to-converter gasket saved in step 6. Position the catalyst flange onto manifold studs and tighten the exhaust manifold fasteners to 24 ft-lbs (32 N.m). 15. Install the downstream oxygen sensor that was removed in step 4 using Miller Special Tool C-4907. Tighten the sensor to 20 ft-lbs (28 N.m). 16. Connect the downstream oxygen sensor electrical connector. 17. For vehicles equipped with a 2.5L engine, connect the upstream oxygen sensor electrical connector. 18. Lower the vehicle. B. Install an Authorized Modifications Label For vehicles involved in Recall # 7932 located in California only: Type or print (with a ball point pen) the following information on an Authorized Modification Label (PN 4275086) and attach the label near the VECI label (Figure 2). C. Complete Proof of Correction Form For vehicles involved in Recall # 7932 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7931 and # 7932 -- Catalytic Converter ^ This service requirement applies only to 1998 model year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) vehicles built from March 1, 1998 through March 21, 1998 (MDH 0301XX through 0321XX) and equipped with a: ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 ^ The catalytic converter on the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition the catalytic converter must be replaced. ^ Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for Advance Service Information (ASI) # 98-17 is being canceled. Vehicles that have had the ASI repair performed have been removed from this recall. ^ For vehicles involved in Recall # 7932 located in California: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-O16-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Due to the small number of involved vehicles no parts will be distributed for this recall. 7931/7932 Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S CATALYTIC CONVERTER Dear Cirrus, Stratus, or Breeze Owner: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 2835 It has been determined that some 1998 Chrysler Cirrus, Dodge Stratus, and Plymouth Breeze vehicles may be in violation of California Emissions Standards. The problem is... The catalytic converter on your Cirrus, Stratus, or Breeze vehicle (identified on the enclosed form), may have been improperly welded, causing it to fail prematurely. This could result in hydrocarbon (HG), carbon monoxide (CO) and oxides of nitrogen (NOx) emission levels above the allowable limits, which were established to protect the public health from the dangers of air pollution. HG emissions consist of unburned fuel that is released into the atmosphere. HG in combination with NOx in the presence of sunlight, can cause the formation of ozone. CO emissions are formed by the incomplete combustion of fuel. These pollutants are the primary components of smog. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The service will take about one hour, but additional time may be required depending on how service work is scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. 7932 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective Technical Service Bulletin # 7931 Date: 981201 Recall - Catalytic Converter Defective No. 7931 December, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7931 and # 7932 -- Catalytic Converter Models: 1998 Model Year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) Vehicles Built From March 1, 1998 Through March 21, 1998 (MDH 0301XX Through 0321XX) ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 The catalytic converter on about 1,500 of the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition, the catalytic converter must be replaced. IMPORTANT: This recall (# 7932) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7932 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system type "53" at the "ENTER FUNCTION" prompt, then type "ORD7931" (Federal emission vehicles) or "ORD7932" (California emission vehicles). Parts IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which catalytic converter is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate converter for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the following table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL. System Function 53 (involved dealers); or Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 2841 ^ Entering the VIN to DIAL System VIP Function (sales code information) along with the table (all dealers). Recall Completion Label Requirement For vehicles involved in Recall # 7932 there is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. Dealers are requested to order the required Authorized Modifications Label PN 04275086 as necessary to support scheduled repairs. Refer to the Service Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Copies of the owner notification letters are included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace catalytic converter 11793182 0.6 hours Add the cost of the catalytic converter plus applicable dealer allowance to your claim. Parts Return Removed catalytic converters must be returned to the Warranty Material Return Center. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Catalytic Converter 1. Raise vehicle on an appropriate hoist. 2. Loosen the exhaust clamp at catalytic converter to resonator slip joint. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 2842 3. Disconnect the downstream oxygen sensor electrical connector. 4. Using Miller Special Tool C-4907 remove the downstream oxygen sensor from the catalytic converter pipe. Mark and save the oxygen sensor for later reuse. (Figure 1). Caution: Upstream and downstream oxygen sensors are not interchangeable. Mark the sensors so that they can be transferred to their correct locations on the new catalyst. 5. For vehicles equipped with a 2.5L engine, disconnect the upstream oxygen sensor electrical connector. 6. Remove the catalytic converter to exhaust manifold fasteners. Save the fasteners and gasket for later reuse. 7. Disconnect the muffler ground strap, exhaust system hangers, and then lower the entire exhaust system to the floor. 8. For vehicles equipped with a 2.5L engine, use Miller Special Tool C-4907 to remove the upstream oxygen sensor from the catalytic converter. Mark and save the oxygen sensor for later reuse (Figure 1). 9. Separate the catalytic converter from the resonator and set it aside for ri3turn to the Warranty Material Return Center. 10. Connect the new catalytic converter assembly to the resonator. Tighten the catalytic converter to resonator clamp to 47 ft-lbs (64 N.m). 11. For vehicles equipped with a 2.5L engine, install the upstream oxygen sensor that was removed in step 8 using Miller Special Tool C-4907. Tighten the sensor to 20 ft lbs (28 N.m). Caution: Upstream and downstream oxygen sensors are not interchangeable. Be sure to install the upstream oxygen sensor in the correct location. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 2843 12. Raise the exhaust system into position and connect the exhaust system hangers. 13. Install the muffler ground strap. 14. Install the manifold-to-converter gasket saved in step 6. Position the catalyst flange onto manifold studs and tighten the exhaust manifold fasteners to 24 ft-lbs (32 N.m). 15. Install the downstream oxygen sensor that was removed in step 4 using Miller Special Tool C-4907. Tighten the sensor to 20 ft-lbs (28 N.m). 16. Connect the downstream oxygen sensor electrical connector. 17. For vehicles equipped with a 2.5L engine, connect the upstream oxygen sensor electrical connector. 18. Lower the vehicle. B. Install an Authorized Modifications Label For vehicles involved in Recall # 7932 located in California only: Type or print (with a ball point pen) the following information on an Authorized Modification Label (PN 4275086) and attach the label near the VECI label (Figure 2). C. Complete Proof of Correction Form For vehicles involved in Recall # 7932 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7931 and # 7932 -- Catalytic Converter ^ This service requirement applies only to 1998 model year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) vehicles built from March 1, 1998 through March 21, 1998 (MDH 0301XX through 0321XX) and equipped with a: ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 ^ The catalytic converter on the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition the catalytic converter must be replaced. ^ Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for Advance Service Information (ASI) # 98-17 is being canceled. Vehicles that have had the ASI repair performed have been removed from this recall. ^ For vehicles involved in Recall # 7932 located in California: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-O16-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Due to the small number of involved vehicles no parts will be distributed for this recall. 7931/7932 Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S CATALYTIC CONVERTER Dear Cirrus, Stratus or Breeze Owner: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7931 > Dec > 98 > Recall - Catalytic Converter Defective > Page 2844 Chrysler Corporation has determined that some 1998 Chrysler Cirrus, Dodge Stratus and Plymouth Breeze vehicles may be in violation of Federal Emissions Standards. The problem is... The catalytic converter on your Cirrus, Stratus or Breeze vehicle (identified on the enclosed form), may have been improperly welded, causing it to fail prematurely. This could result in hydrocarbon (HC), carbon monoxide (CO) and oxides of nitrogen (NOx) levels above the allowable limits which were established to protect the public health from the dangers of air pollution. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C. 20460. In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test. We are sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks for your attention to this important matter. 7931 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect Technical Service Bulletin # 7932 Date: 981201 Recall - Catalytic Converter Defect No. 7932 December, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Emissions Recalls # 7931 and # 7932 -- Catalytic Converter Models: 1998 Model Year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) Vehicles Built From March 1, 1998 Through March 21, 1998 (MDH 0301XX Through 0321XX) ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 The catalytic converter on about 1,500 of the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition, the catalytic converter must be replaced. IMPORTANT: This recall (# 7932) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall # 7932 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name address and phone number is listed if known. Parts information is also provided. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system type "53" at the "ENTER FUNCTION" prompt, then type "ORD7931" (Federal emission vehicles) or "ORD7932" (California emission vehicles). Parts IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers. Parts may be ordered as needed to support scheduled repairs. Dealers should determine which catalytic converter is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate converter for the vehicle to be serviced may be determined by: ^ Using the part code in the third column of the VIN list along with the following table (involved dealers); ^ Using the VIN and part number list electronically transmitted to DIAL. System Function 53 (involved dealers); or Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 2849 ^ Entering the VIN to DIAL System VIP Function (sales code information) along with the table (all dealers). Recall Completion Label Requirement For vehicles involved in Recall # 7932 there is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. Dealers are requested to order the required Authorized Modifications Label PN 04275086 as necessary to support scheduled repairs. Refer to the Service Procedure of this letter for application instructions. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. Copies of the owner notification letters are included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Replace catalytic converter 11793182 0.6 hours Add the cost of the catalytic converter plus applicable dealer allowance to your claim. Parts Return Removed catalytic converters must be returned to the Warranty Material Return Center. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Catalytic Converter 1. Raise vehicle on an appropriate hoist. 2. Loosen the exhaust clamp at catalytic converter to resonator slip joint. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 2850 3. Disconnect the downstream oxygen sensor electrical connector. 4. Using Miller Special Tool C-4907 remove the downstream oxygen sensor from the catalytic converter pipe. Mark and save the oxygen sensor for later reuse. (Figure 1). Caution: Upstream and downstream oxygen sensors are not interchangeable. Mark the sensors so that they can be transferred to their correct locations on the new catalyst. 5. For vehicles equipped with a 2.5L engine, disconnect the upstream oxygen sensor electrical connector. 6. Remove the catalytic converter to exhaust manifold fasteners. Save the fasteners and gasket for later reuse. 7. Disconnect the muffler ground strap, exhaust system hangers, and then lower the entire exhaust system to the floor. 8. For vehicles equipped with a 2.5L engine, use Miller Special Tool C-4907 to remove the upstream oxygen sensor from the catalytic converter. Mark and save the oxygen sensor for later reuse (Figure 1). 9. Separate the catalytic converter from the resonator and set it aside for ri3turn to the Warranty Material Return Center. 10. Connect the new catalytic converter assembly to the resonator. Tighten the catalytic converter to resonator clamp to 47 ft-lbs (64 N.m). 11. For vehicles equipped with a 2.5L engine, install the upstream oxygen sensor that was removed in step 8 using Miller Special Tool C-4907. Tighten the sensor to 20 ft lbs (28 N.m). Caution: Upstream and downstream oxygen sensors are not interchangeable. Be sure to install the upstream oxygen sensor in the correct location. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 2851 12. Raise the exhaust system into position and connect the exhaust system hangers. 13. Install the muffler ground strap. 14. Install the manifold-to-converter gasket saved in step 6. Position the catalyst flange onto manifold studs and tighten the exhaust manifold fasteners to 24 ft-lbs (32 N.m). 15. Install the downstream oxygen sensor that was removed in step 4 using Miller Special Tool C-4907. Tighten the sensor to 20 ft-lbs (28 N.m). 16. Connect the downstream oxygen sensor electrical connector. 17. For vehicles equipped with a 2.5L engine, connect the upstream oxygen sensor electrical connector. 18. Lower the vehicle. B. Install an Authorized Modifications Label For vehicles involved in Recall # 7932 located in California only: Type or print (with a ball point pen) the following information on an Authorized Modification Label (PN 4275086) and attach the label near the VECI label (Figure 2). C. Complete Proof of Correction Form For vehicles involved in Recall # 7932 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Dealer Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Emissions Recalls # 7931 and # 7932 -- Catalytic Converter ^ This service requirement applies only to 1998 model year Chrysler Cirrus, Dodge Stratus and Plymouth Breeze (JA) vehicles built from March 1, 1998 through March 21, 1998 (MDH 0301XX through 0321XX) and equipped with a: ^ Federal Emission Control System (Sales Code -- NAA) -- Recall # 7931 ^ California Emission Control System (Sales Code -- NAE) -- Recall # 7932 ^ The catalytic converter on the above listed vehicles may have been welded with incorrect weld wire. This may result in corrosion of the converter weld joints and cause premature failure of the catalytic converter. To correct this condition the catalytic converter must be replaced. ^ Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for Advance Service Information (ASI) # 98-17 is being canceled. Vehicles that have had the ASI repair performed have been removed from this recall. ^ For vehicles involved in Recall # 7932 located in California: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-O16-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^ Due to the small number of involved vehicles no parts will be distributed for this recall. 7931/7932 Owner Letter EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S CATALYTIC CONVERTER Dear Cirrus, Stratus, or Breeze Owner: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 7932 > Dec > 98 > Recall - Catalytic Converter Defect > Page 2852 It has been determined that some 1998 Chrysler Cirrus, Dodge Stratus, and Plymouth Breeze vehicles may be in violation of California Emissions Standards. The problem is... The catalytic converter on your Cirrus, Stratus, or Breeze vehicle (identified on the enclosed form), may have been improperly welded, causing it to fail prematurely. This could result in hydrocarbon (HG), carbon monoxide (CO) and oxides of nitrogen (NOx) emission levels above the allowable limits, which were established to protect the public health from the dangers of air pollution. HG emissions consist of unburned fuel that is released into the atmosphere. HG in combination with NOx in the presence of sunlight, can cause the formation of ozone. CO emissions are formed by the incomplete combustion of fuel. These pollutants are the primary components of smog. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The service will take about one hour, but additional time may be required depending on how service work is scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. 7932 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2853 Fig. 1 Exhaust System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2854 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalytic Converter Operation > Page 2857 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2858 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Converter Servicing Catalytic Converter: Service and Repair Converter Servicing There is no regularly scheduled maintenance on the catalytic converter. If damaged, the converter must be replaced. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country (particularly vehicles built for States with strict emission requirements). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Converter Servicing > Page 2861 Catalytic Converter: Service and Repair Replacement 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Converter Servicing > Page 2862 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. Remove catalytic converter to exhaust manifold attaching fasteners. Remove catalytic converter from vehicle. 7. 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. Installation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Converter Servicing > Page 2863 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.). 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Fig 24 Proportional Purge Solenoid Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2868 Proportional Purge Solenoid Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2869 Canister Purge Solenoid: Description and Operation Fig 24 Proportional Purge Solenoid PURPOSE The Proportional 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 proportional purge solenoid operates at a frequency of 200 Hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2870 Canister Purge Solenoid: Testing and 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations ORVR System The canister mounts to a bracket on top of the fuel tank in the rear of the vehicle. The vacuum and vapor tube connect to the top of the canister. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2874 Evaporative Emission Control Canister: Description and Operation ORVR System 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 filled evaporative canister. The canister temporarily holds the vapors. The PCM allows intake manifold vacuum to draw vapors from the charcoal canister into the combustion chambers during certain operating conditions. This vehicle uses a proportional purge system. The PCM controls vapor flow by operating the purge solenoid. 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 proportional EVAP purge solenoid. The PCM purges the canister at predetermined intervals and engine conditions. The canister mounts to a bracket on top of the fuel tank in the rear of the vehicle. The vacuum and vapor tube connect to the top of the canister. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2875 Evaporative Emission Control Canister: Service and Repair Fig 20 Fuel Tank Assembly Fig 21 EVAP System REMOVAL 1. Release fuel pressure. Fig 22 Battery Cable Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2876 Fig 23 EVAP System Fig 24 Fuel Tank Drain 2. Disconnect battery cable (Fig. 22). 3. Raise vehicle and support. 4. Drain fuel tank. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2877 Fig 25 Fuel Filler Tube 5. Loosen and remove fuel filler tube from fuel tank (Fig. 25). Fig 26 Fuel Line 6. Disconnect fuel line (Fig. 26). 7. Position transmission jack under fuel tank assembly. 8. Remove fuel tank straps bolts. Passenger side first. Fig 27 EVAP Components 9. Lower fuel tank and remove the purge line and vent line (Fig. 27). 10. Remove hoses from EVAP canister. 11. Disconnect electrical connector for Leak Detection Pump (LDP). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2878 Fig 28 LDP And EVAP Canister 12. Remove push pin from bracket for EVAP canister (Fig. 28). - Remove canister. INSTALLATION 1. Install EVAP canister to bracket install push pin. 2. Install hoses and lines. 3. Raise the fuel tank on the transmission stand. 4. Connect the purge and vent lines. 5. Connect LDP and fuel pump electrical connector. 6. Raise tank into position and install tank straps. 7. Install the fuel filler tube and tighten the clamp. 8. Lower vehicle. 9. Connect the battery cable. 10. Fill fuel tank. Use the DRB scan tool to pressurize the fuel system. Check for leaks. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations EVAP System Test Port Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions Leak Detection Pump: Technical Service Bulletins Emissions - EGR/EVAP Test Revisions NUMBER: 26-05-98L GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L, 2.4L, 2.5L Dodge, Plymouth Powertrain Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the EGR Solenoid test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2886 120 Revisions to the Evap Leak detection tests Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2887 522 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2888 523 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2889 524 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2890 525 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2891 525A Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2892 525B Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2893 526 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2894 527 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2895 528 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2896 529 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2897 529A Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2898 529B Revisions to the Leak detection pump switch test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2899 540 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2900 543 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2901 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2902 Fuel Tank, EVAP Canister, LDP Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2903 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2904 Leak Detection Pump: Description and Operation Leak Detection Pump (LDP) Operation And Diagnosis This bulletin describes the theory of operation for the leak detection system. In addition, information is provided for each of the Diagnostic Trouble Codes (DTC's) as follows: P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT INTRODUCTION The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2905 EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2906 LDP AT REST (NOT POWERED) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2907 DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2908 DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2909 Leak Detection Pump: Testing and Inspection ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40° F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2. Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP leak detection test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and 85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following: - Purge Solenoid Electrical Fault - All Engine Controller Self Test Faults - All Cam And/or Crank Sensor Fault - All Map Sensor Faults - Ambient/battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Fault - EGR Solenoid Fault - All Injector Faults - Baro Our Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2910 Figure 6 EVAP leak detection test sequence When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is canceled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P0441. These temperature calibrations may be different between models. FIGURE 6 SECTION 2 If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2911 illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. FIGURE 6 SECTION 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. FIGURE 6 SECTION 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. FIGURE 6 SECTION 5 Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned off. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. DIAGNOSTIC TIPS During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can set due to pressure being in the EVAP system during the test sequence. Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing or high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. TEST EQUIPMENT The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2912 the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. IMPORTANT Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2913 Leak Detection Pump: Service and Repair Fig 11 Fuel Tank Assembly Fig 12 EVAP System REMOVAL 1. Release fuel pressure. Fig 13 Battery Cable Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2914 Fig 14 EVAP System Fig 15 Fuel Tank Drain 2. Disconnect battery cable (Fig. 13). 3. Raise vehicle and support. 4. Drain fuel tank. Fig 16 Fuel Filler Tube Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2915 5. Loosen and remove fuel filler tube from fuel tank (Fig. 16). Fig 17 Fuel Line 6. Disconnect fuel line (Fig. 17). 7. Position transmission jack under fuel tank assembly. 8. Remove fuel tank straps bolts. Passenger side first. Fig 18 EVAP Components 9. Lower fuel tank and remove the purge line and vent line (Fig. 18). 10. Remove hoses from EVAP canister. 11. Disconnect electrical connector for Leak Detection Pump (LDP). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2916 Fig 19 LDP And EVAP Canister 12. Remove push pin from bracket for EVAP canister (Fig. 19). 13. Remove bracket and Leak Detection Pump. 14. Remove LDP from bracket. INSTALLATION 1. Install LDP onto bracket. 2. Install bracket and LDP onto fuel tank assembly. 3. Install EVAP canister to bracket install push pin. 4. Install hoses and lines. 5. Raise the fuel tank on the transmission stand. 6. Connect the purge and vent lines. 7. Connect LDP and fuel pump electrical connector. 8. Raise tank into position and install tank straps. 9. Install the fuel filler tube and tighten the clamp. 10. Lower vehicle. 11. Connect the battery cable. 12. Fill fuel tank. Use the DRB scan tool to pressurize the fuel system. Check for leaks. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions Leak Detection Solenoid: Technical Service Bulletins Emissions - EGR/EVAP Test Revisions NUMBER: 26-05-98L GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L, 2.4L, 2.5L Dodge, Plymouth Powertrain Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the EGR Solenoid test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2921 120 Revisions to the Evap Leak detection tests Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2922 522 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2923 523 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2924 524 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2925 525 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2926 525A Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2927 525B Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2928 526 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2929 527 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2930 528 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2931 529 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2932 529A Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2933 529B Revisions to the Leak detection pump switch test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2934 540 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2935 543 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest: > 25-001-02A > Sep > 02 > EVAP System - MIL ON/DTC's Set (EVAP) Leak Detection Valve: Customer Interest EVAP System - MIL ON/DTC's Set (EVAP) NUMBER: 25-001-02 REV A GROUP: Emissions DATE: Sept. 2, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 25-001-02 DATED FEBRUARY 11, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** INCLUDES ADDITIONAL MODELS AND CORRECTS A MODEL AND YEAR ERROR. SUBJECT: MIL Illumination, DTC P0442, P0455, or P0456 - Leak Detection Pump (LDP), Leak Detected OVERVIEW: This bulletin involves a new diagnostic test for the LDP system. MODELS: **1998 - 1999 (JA) Breeze/Cirrus/Stratus** **1999 (JX) Sebring Convertible** ** 1998 - 2001 ** (LH) Concorde/Intrepid/LHS/300M 2001 - 2002 (RS) Town & Country/Caravan/Voyager **2002** (WJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO JA AND JX MODEL EQUIPPED WITH CALIFORNIA EMISSIONS (SALES CODE NAE). SYMPTOM/CONDITION: MIL illumination with one of the following DTC: ^ P0442 EVAP Leak Monitor .040 Leak Detected (Medium Leak) ^ P0455 EVAP Leak Monitor Large Leak Detected ^ P0456 EVAP Leak Monitor .020 Leak Detected (Small Leak) DIAGNOSIS: If one of the above DTC's are present, perform this diagnostic test first before proceeding with the diagnostic procedures in the appropriate Powertrain Diagnostic Procedure Manual. Raise the vehicle on an appropriate hoist. Locate the LDP vent valve. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest: > 25-001-02A > Sep > 02 > EVAP System - MIL ON/DTC's Set (EVAP) > Page 2944 Remove the vacuum hose from the top of the vent valve (Fig. 1). Attach a hand vacuum pump to the vent valve and apply 20" Hg. vacuum. Observe the vacuum for 10 seconds. If the vacuum holds between 15.5" Hg. and 20" Hg., refer to the appropriate Powertrain Diagnostic Procedure Manual, MDS2, or the Leak Detection Pump Operation and Diagnosis booklet (Publication No. 81-170-000606) for further diagnosis. If the vacuum drops below 15.5" Hg., obtain the appropriate LDP vent valve using the Mopar parts catalog and perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the left rear wheel (WJ only). 2. Remove the hose at the top rear of the evaporative canister to ease vent valve removal (WJ only). 3. Remove all clamps and all hoses attached to the vent valve. 4. Install new vent valve. Ensure all hoses, clamps and the vacuum hose to the top of the vent valve are securely attached. 5. Attach the hose at the top rear of the evaporative canister (WJ only) 6. Install wheelhouse splash shield using five plastic rivets (WJ only). 7. Install left rear wheel (WJ only). 8. Lower vehicle. 9. Use the DRBIII(R) to erase the DTC. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest: > 25-001-02A > Sep > 02 > EVAP System - MIL ON/DTC's Set (EVAP) > Page 2945 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 25-001-02A > Sep > 02 > EVAP System - MIL ON/DTC's Set (EVAP) Leak Detection Valve: All Technical Service Bulletins EVAP System - MIL ON/DTC's Set (EVAP) NUMBER: 25-001-02 REV A GROUP: Emissions DATE: Sept. 2, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 25-001-02 DATED FEBRUARY 11, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** INCLUDES ADDITIONAL MODELS AND CORRECTS A MODEL AND YEAR ERROR. SUBJECT: MIL Illumination, DTC P0442, P0455, or P0456 - Leak Detection Pump (LDP), Leak Detected OVERVIEW: This bulletin involves a new diagnostic test for the LDP system. MODELS: **1998 - 1999 (JA) Breeze/Cirrus/Stratus** **1999 (JX) Sebring Convertible** ** 1998 - 2001 ** (LH) Concorde/Intrepid/LHS/300M 2001 - 2002 (RS) Town & Country/Caravan/Voyager **2002** (WJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO JA AND JX MODEL EQUIPPED WITH CALIFORNIA EMISSIONS (SALES CODE NAE). SYMPTOM/CONDITION: MIL illumination with one of the following DTC: ^ P0442 EVAP Leak Monitor .040 Leak Detected (Medium Leak) ^ P0455 EVAP Leak Monitor Large Leak Detected ^ P0456 EVAP Leak Monitor .020 Leak Detected (Small Leak) DIAGNOSIS: If one of the above DTC's are present, perform this diagnostic test first before proceeding with the diagnostic procedures in the appropriate Powertrain Diagnostic Procedure Manual. Raise the vehicle on an appropriate hoist. Locate the LDP vent valve. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 25-001-02A > Sep > 02 > EVAP System - MIL ON/DTC's Set (EVAP) > Page 2951 Remove the vacuum hose from the top of the vent valve (Fig. 1). Attach a hand vacuum pump to the vent valve and apply 20" Hg. vacuum. Observe the vacuum for 10 seconds. If the vacuum holds between 15.5" Hg. and 20" Hg., refer to the appropriate Powertrain Diagnostic Procedure Manual, MDS2, or the Leak Detection Pump Operation and Diagnosis booklet (Publication No. 81-170-000606) for further diagnosis. If the vacuum drops below 15.5" Hg., obtain the appropriate LDP vent valve using the Mopar parts catalog and perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the left rear wheel (WJ only). 2. Remove the hose at the top rear of the evaporative canister to ease vent valve removal (WJ only). 3. Remove all clamps and all hoses attached to the vent valve. 4. Install new vent valve. Ensure all hoses, clamps and the vacuum hose to the top of the vent valve are securely attached. 5. Attach the hose at the top rear of the evaporative canister (WJ only) 6. Install wheelhouse splash shield using five plastic rivets (WJ only). 7. Install left rear wheel (WJ only). 8. Lower vehicle. 9. Use the DRBIII(R) to erase the DTC. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 25-001-02A > Sep > 02 > EVAP System - MIL ON/DTC's Set (EVAP) > Page 2952 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Leak Detection Valve: > 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Leak Detection Valve: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 2958 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Leak Detection Valve: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 2964 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Testing and Inspection 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. NOTE: Electrical operation of the solenoid should be checked with the DRB scan tool before proceeding with the vacuum test. 1. Disconnect the rubber back-pressure hose from the fitting at the bottom of the transducer. 2. Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If vacuum falls off, the transducer diaphragm is leaking. 5. Replace the transducer and EGR valve assembly. Connect the rubber hose to the transducer and proceed to next step for further testing. 6. Reconnect the hose to the EGR valve. 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. A DTC will be set in the PCM that must be erased after testing is complete. 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. - To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present at valve. It must be high enough to hold the bleed valve in the transducer protion of the valve closed. - Have a helper momentarily -- for a second or two -- hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the vacuum gauge. Heavy gloves should be worn. CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. - 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. NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Testing and Inspection > Page 2969 EGR Backpressure Transducer: Service and Repair Fig. 1 EGR System 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 and transducer/solenoid attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. 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 lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lbs) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions EGR Control Solenoid: Technical Service Bulletins Emissions - EGR/EVAP Test Revisions NUMBER: 26-05-98L GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 2.0L, 2.4L, 2.5L Dodge, Plymouth Powertrain Diagnostic Manual - Publication Number 81-699-97108 DESCRIPTION OF CHANGES Revisions to the EGR Solenoid test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2974 120 Revisions to the Evap Leak detection tests Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2975 522 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2976 523 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2977 524 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2978 525 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2979 525A Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2980 525B Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2981 526 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2982 527 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2983 528 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2984 529 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2985 529A Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2986 529B Revisions to the Leak detection pump switch test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2987 540 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Emissions - EGR/EVAP Test Revisions > Page 2988 543 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Page 2989 EGR Control Solenoid: Locations CAM Sensor,EGR Transducer, Service Port Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > Page 2990 EGR Solenoid Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Electronic EGR Transducer (EET) Solenoid Operation EGR Control Solenoid: Description and Operation Electronic EGR Transducer (EET) Solenoid Operation Fig. 27 Electronic EGR Transducer 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. Fig. 28 Electric EGR Transducer The solenoid/transducer and EGR valve mount to the rear of the cylinder head Fig. 28. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Electronic EGR Transducer (EET) Solenoid Operation > Page 2993 EGR Control Solenoid: Description and Operation EGR Solenoid Circuit NAME OF CODE: EGR Solenoid Circuit WHEN MONITORED: With the ignition key ON and engine running. SET CONDITION: The EGR solenoid control circuit is not in the expected state when requested to operate by the Powertrain Control Module (PCM). THEORY OF OPERATION: The EGR solenoid is actuated by the PCM when the engine is at normal operating temperature. Throttle position sensor shows other than idle or wide open throttle (WOT) and manifold absolute pressure (MAP) is in mid operating range. The PCM looks for a current spike when actuating the solenoid. If the spike is not present the PCM sets a trouble code. POSSIBLE CAUSES: - Open or shorted control circuit - Open fused ignition switch output circuit - Open or shorted solenoid control coil - Powertrain control module failure Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Page 2994 EGR Control Solenoid: Testing and Inspection Electrical operation of the valve control should be checked with a scan tool. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Tube to Intake Torque 95 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 2998 EGR Tube: Service and Repair Fig. 7 EGR Tube Stud Bolts NOTE: The EGR tube attaches to the intake manifold plenum below the throttle body and to the EGR valve (Fig. 1). REMOVAL 1. Remove screws attaching EGR tube to intake manifold (Fig. 7). 2. Remove EGR tube to EGR valve screws. 3. Remove EGR tube. Clean gasket surface on the EGR valve. Wipe the grommet clean on the intake manifold. NOTE: The rubber grommet that seals the EGR tube to intake manifold connection is reusable. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3002 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation Fig. 7 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3006 Fig. 11 Moderate Intake Manifold Vacuum--Maximum Vapor Flow 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). Crankcase Vent Filter All engines use filtered air to vent the crankcase. The filtered air is drawn through the resonator assembly located between the air cleaner and throttle body. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3007 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fig. 1 Fuel Pressure Test Port--Typical Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3016 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 ................................................................................ .............................................................................................. 550 - 1,300 rpm Odometer >= 1,000 miles .................................................................................................................................................... .......................... 600 - 1,300 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3020 Idle Speed: Testing and Inspection Fig. 34 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. 34. Fig. 36 Orifice 6457 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. 36. 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 ............................................................................................................................. ........................................... 550 - 1,300 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 600 - 1,300 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. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3021 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3025 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels > Page 3034 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3035 Fuel: Specifications FUEL REQUIREMENTS The vehicle is designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline having a minimum octane rating of 87. The vehicle will operate on fuels ranging from regular unleaded having a minimum posted octane of 87 to premium unleaded with a minimum posted octane of 91. However, mid-grade unleaded fuel with a minimum octane rating of 89 is recommended. The use of premium unleaded gasoline will further improve performance. If the vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful. However; continued heavy spark knock at high speeds can cause damage and should be corrected immediately. Engine damage as a result of heavy spark knock operation may not be covered by the new vehicle warranty. In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended. Using gasoline that has these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. ADDITIVES & OXYGENATE BLENDS Additives - The use of gasoline containing detergents, corrosion and stability additives is recommended, as these additives will improve fuel economy, reduce emissions, and maintain vehicle performance. Fuel Quality - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. Pinging/Knocking - Light knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and should be reported to your dealer immediately. CAUTION: Engine damage resulting from operating with a heavy spark knock may not be covered by the new vehicle warranty. GASOLINE/OXYGENATE BLENDS Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle. Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other alcohols called cosolvents. CAUTION: Do not use gasoline containing Methanol. Use of methanol/gasoline blends may result in starting and driveability problems and damage critical fuel system components. Problems that are the result of using methanol/gasoline blends may not be covered by the new vehicle warranty. CLEAN AIR GASOLINE MTBE/ETBE - Many gasoline are now being blended that contribute to cleaner air, especially in those areas of the country where pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as reformulated gasoline.. MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline blended with MTBE may be used in your vehicle. ETBE (Ethyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to up to 17 percent ETBE. Gasoline blended with ETBE may be used in your vehicle. ADDITIVE CAUTION: Many materials intended for gum and varnish removal may contain active solvents or similar ingredients that can be harmful to fuel system gasket and diaphragm materials. Indiscriminate use of fuel system cleaning agents should be avoided. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications > Page 3039 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3044 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 2 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from auxiliary jumper terminal. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3049 Fuel Injector: Pressure, Vacuum and Temperature Specifications Information not supplied by the manufacturer. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3050 Injector, Fuel Service Port Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3051 Injector #1 Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3052 Fuel Injector: Description and Operation 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Resistance Test 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Resistance Test > Page 3055 Fuel Injector Diagnosis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3056 Fuel Injector: Service and Repair Fig. 17 Fuel Injector Clip REPLACEMENT 1. Remove Fuel Rail. 2. Remove fuel injector clip Fig. 17. 3. Pull injector out of fuel rail. Replace fuel injector 0-rings. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3060 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3061 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 (L4-2.4L VIN X (1998)) 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 (48 psi) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3065 Fuel Pump Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3066 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3067 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3068 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Fig. 1 Fuel Pressure Test Port--Typical Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fig. 1 Fuel Pressure Test Port--Typical Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Component Locations Fuel Pump Relay: Component Locations Power Distribution Center, Fuel Pump Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 3081 Power Distribution Center Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 3082 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3083 Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3084 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3085 Fuel Pump Relay: Testing and Inspection Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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. TEST Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3086 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Bolts ..................................................................................................................................... ................................................... 22.5 Nm (200 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3090 Fuel Rail: Service and Repair Fig 28 Fuel Rail And Injectors Fig. 16 Fuel Rail And Injectors 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 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. Refer to Quick-Connect Fittings in the Fuel Delivery and Air Induction/Fuel Line Coupler . See: Fuel Line Coupler/Service and Repair 4. Disconnect electrical connectors from fuel injectors Fig. 16. 5. Remove fuel rail mounting screws. 6. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold. INSTALLATION 1. Apply a light coating of clean engine oil to the 0-ring on the nozzle end of each injector. 2. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail mounting screws to 22.5 Nm ± 3 Nm (2OO ± 3O in. lbs.). 3. Attach electrical connectors to fuel injectors. 4. Connect fuel supply tube to fuel rail. See: Service and Repair/Quick Connect Fittings 5. Connect negative cable to auxiliary jumper terminal. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications Sending Unit Resistance Chart Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Drain Plug > Component Information > Specifications > Page 3101 Fig 15 Fuel Tank Drain Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure Release Valve > Component Information > Description and Operation Fuel Tank Pressure Release Valve: Description and Operation ORVR System Schematic CONTROL VALVE/PRESSURE RELIEF If the fuel tank should over-pressurize, the control valve incorporates a pressure relief port that allows pressure relief capability under extreme conditions. Example, if the canister vent line was to get pinched or obstructed, the relief valve would vent the pressure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3108 Fuel Pump Module, Fuel Line, Fuel Filter Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3109 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3110 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 Pressure Release procedure before servicing the fuel pump. 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 Pressure Release procedure. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3111 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3112 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3113 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3114 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3115 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3116 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Motor to throttle Body Bolts Torque 25 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3120 Idle Speed/Throttle Actuator - Electronic: Locations Idle Air Control Motor, Throttle Shield, Throttle Position Sensor Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3121 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3122 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig. 31 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). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3123 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 25 Throttle Position Sensor And Idle Air Control Motor The idle air control motor attaches to the side of the throttle body Fig. 25. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3127 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3128 Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3129 Automatic Shut Down (ASD) Relay: Description and Operation Fig 12 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 Power Distribution Center (PDC) -- located in the engine compartment. The inside top of the PDC cover has label showing relay and fuse identification. Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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 (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test > Page 3132 TEST 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations Fuel Pump Relay: Component Locations Power Distribution Center, Fuel Pump Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 3138 Power Distribution Center Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Component Locations > Page 3139 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3140 Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3141 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3142 Fuel Pump Relay: Testing and Inspection Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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. TEST Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3143 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3147 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3148 Power Distribution Center, Auto Shutdown Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3149 Automatic Shut Down (ASD) Relay: Description and Operation Fig 12 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 Power Distribution Center (PDC) -- located in the engine compartment. The inside top of the PDC cover has label showing relay and fuse identification. Fig. 1 ASD And Fuel Pump Relay Terminals Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: 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 (L4-2.4L VIN X (1998)) 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 > Fuel Pump & ASD Relay Test > Page 3152 TEST 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 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) 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 heavier) 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 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. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation > Page 3156 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3162 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3163 Fig. 35 Throttle Position Sensor And Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3164 Throttle Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3165 Throttle Position Sensor: Description and Operation Fig. 22 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 mounts to the side of the throttle body Fig. 22. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 > Component Testing 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3168 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3169 Throttle Position Sensor: Service and Repair Fig. 35 Throttle Position Sensor And Idle Air Control Motor THROTTLE POSITION SENSOR (TPS) SERVICE The throttle position sensor attaches to the side of the throttle body Fig. 35. 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 throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 36 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 36. - 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Mounting Bolt Torque 19 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3173 Throttle Body: Description and Operation Fig. 33 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. 33. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3174 Throttle Body: Testing and Inspection Fig. 34 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. 34. Fig. 36 Orifice 6457 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. 36. 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 ............................................................................................................................. ........................................... 550 - 1,300 rpm - Above 1,000 miles ............................................................................................................................. ........................................... 600 - 1,300 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. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3175 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 (L4-2.4L VIN X (1998)) 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. 4 Throttle Cable Attachment To Throttle Body Fig. 5 Disconnecting Throttle Cable THROTTLE BODY - REMOVAL 1. Remove air inlet resonator. 2. Remove throttle cable from the throttle body lever Figs. 4 and 5. 3. Compress the retaining tabs on the cable and slide cable out of bracket Fig. 4. 4. If equipped with speed control, remove speed control cable from throttle lever by sliding clasp out hole used for throttle cable. 5. Remove EVAP purge hose from nipple on throttle body. 6. Remove 2 screws holding cable mounting bracket and support bracket. 7. Remove throttle body mounting bolts. 8. Lift throttle body far enough to remove connectors from the throttle position sensor and idle air control motor. Remove throttle body. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Replacement > Page 3178 Fig. 6 Re-Usable Throttle Body Gasket 9. The rubber 0-ring gasket on the intake manifold is reusable. Wipe the 0-ring clean before installing throttle body Fig. 6. INSTALLATION 1. Attach electrical connectors to idle air control motor and throttle position sensor. 2. Position throttle body on intake and install mounting bolts. DO NOT tighten bolts at this time. 3. Install throttle cable bracket. DO NOT tighten bolts at this time. 4. Tighten throttle body bolts to 22.5 ± 3 Nm (200 ± 25 in. lbs.) torque. 5. Tighten throttle cable bracket bolts to 11.75 ± 2.25 Nm (105 ± 20 in. lbs.) torque. 6. Install EVAP purge hose to throttle body nipple. 7. Install cable housing(s) retainer tabs into bracket. 8. Install throttle body cables by rotating the throttle lever forward to the wide open position Fig. 4. 9. Install air inlet resonator. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Replacement > Page 3179 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Throttle Cable Bracket Bolts ................................................................................................................ ................................................ 11.75 Nm (105 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 3183 Throttle Cable/Linkage: Service and Repair Fig. 2 Throttle Cable Attachment To Throttle Body Fig. 3 Disconnecting Throttle Cable REMOVAL 1. Working from the engine compartment, remove the throttle cable from the throttle body lever Figs 2 and 3. 2. Compress the retaining tabs on the cable and slide cable out of bracket Fig. 3. Fig 46 Cable Routing Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 3184 Fig. 1 Accelerator Pedal And Throttle Cable 3. From inside 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3189 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Screws ......................................................................................................... ........................................................... 3 Nm (25 in lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3190 Fig. 35 Throttle Position Sensor And Idle Air Control Motor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3191 Throttle Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3192 Throttle Position Sensor: Description and Operation Fig. 22 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 mounts to the side of the throttle body Fig. 22. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Testing 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3195 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3196 Throttle Position Sensor: Service and Repair Fig. 35 Throttle Position Sensor And Idle Air Control Motor THROTTLE POSITION SENSOR (TPS) SERVICE The throttle position sensor attaches to the side of the throttle body Fig. 35. 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 throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 36 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS Fig. 36. - 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cable Routing and Firing Order Firing Order Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3211 Camshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Camshaft Sensor Pick Up Bolts ..................................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3212 Camshaft Position Sensor: Locations Crank Shaft Position Sensor Camshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3213 Cam Shaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3214 Camshaft Position Sensor: Description and Operation Fig. 3 Camshaft Position Sensor 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. The sensor also acts as a thrust plate to control camshaft end play. Fig. 4 Target Magnet--Typical Fig. 5 Target Magnet Polarity Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3215 OPERATION The camshaft position sensor attaches to the rear of the cylinder head Fig. 4. A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity Fig. 5. The sensor input switches from high (5 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3216 Camshaft Position Sensor: Service and Repair Fig. 6 Camshaft Position Sensor Location Fig. 7 Target Magnet Removal Fig. 8 Target Magnet Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head Fig. 6. REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. 2. Remove air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove camshaft position sensor mounting screws. Remove sensor. 5. Loosen screw attaching target magnet to rear of camshaft Fig. 7. NOTE: The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3217 INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 4. Install air cleaner inlet tube and filtered air tube -- if applicable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3222 Crankshaft Position Sensor: Mechanical Specifications Sensor Screw Tightening Torque 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3223 Crankshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3224 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3225 Crankshaft Position Sensor: Description and Operation Fig 8 Timing Reference Notches Fig. 6 Timing Reference Notches Fig 9 Crankshaft Position Sensor OPERATION The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The second crankshaft counter-weight has machined into it two sets of four timing reference notches including a 60° signature notch Fig. 6. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3226 If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. The faster the engine is operating, the smaller the pulse-width on the oscilloscope. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69° Before Top Dead Center (BTDC). The second notch represents 49° BTDC. The third notch represents 29°. The last notch in each set represents 9° Before Top Dead Center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Fig. 8 Crankshaft Position Sensor The crankshaft position sensor attaches to the cowl side of the engine block. It is located between the main bearing cap/bed plate assembly and block behind the power steering pump Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3227 Crankshaft Position Sensor: Service and Repair Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter Fig. 9. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable Resistance Cable #1 & #4 3,500 - 4,500 ohms Cable #2 & #3 2,950 - 4,100 ohms Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3231 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and 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. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3234 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 the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - 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, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE CABLE RESISTANCE #1 & #4 3,500 to 4,900 ohms #2 & #3 2,950 to 4,100 ohms 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 40,000 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 3237 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Resistance cables are identified by the words Electronic Suppression. SPARK PLUG CABLE SERVICE The cables insulate the spark plugs and covers the top of the spark plug tube Fig. 3. To remove the cables, lightly grasp the top of the cable. Rotate the insulator 90° and pull straight up. To replace the cables, disconnect the cable from the ignition coil. Ensure the #1 and #4 cables run under the #2 and #3 ignition coil towers. Keep #4 cable away from the oil fill cap. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Resistance Primary 0.51 - 0.61 ohms at 21 - 27 deg C Secondary 11,500 - 13,500 ohms at 21 - 27 deg C Coil to Cylinder Head Torque 12 ft.lb Fig. 2 Terminal Identification Fig. 3 Checking Ignition Coil Secondary Resistance Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3242 Ignition Coil: Mechanical Specifications Coil Resistance Primary 0.51 - 0.61 ohms at 21 - 27 deg C Secondary 11,500 - 13,500 ohms at 21 - 27 deg C Coil to Cylinder Head Torque 12 ft.lb Fig. 2 Terminal Identification Fig. 3 Checking Ignition Coil Secondary Resistance Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3243 Electrical Connector, Ignition Coil Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3244 Ignition Coil Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3245 Ignition Coil: Description and Operation Fig. 12 Ignition Coil Pack WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. OPERATION The coil pack consists of 2 coils molded together. The coil pack is mounted on a bracket, over the valve cover. High tension leads route to each cylinder from the coil. The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the other cylinder fires on the exhaust stroke. Coil number one fires cylinders 1 and 4. Coil number two fires cylinders 2 and 3. The PCM determines which of the coils to charge and fire at the correct time. The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the energy in the coil primary transfers to the secondary causing the spark. The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3246 Ignition Coil: Testing and Inspection Fig. 2 Terminal Identification NOTE: Coil one fires cylinders 1 and 4, coil two fires cylinders 2 and 3. Each coil tower is labeled with the number of the corresponding cylinder. 1. Remove the ignition cables and measure the resistance of the cables. Resistance must be in this range: Coil Resistance @ 21-27°C (70-80°F) Primary 0.51 to 0.61 ohms - Secondary 11,500 to 13,500 ohms Replace any cable not within tolerance. 2. Disconnect the electrical connector from the coil pack. 3. Measure the primary resistance of each coil. At the coil, connect an ohmmeter between the B+ pin and the pin corresponding to the cylinders in question Fig. 2. Resistance on the primary side of each coil should be 0.45 - 0.65 ohm @ 70° - 80° F. Replace the coil if resistance is not within tolerance. Fig. 3 Checking Ignition Coil Secondary Resistance 4. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance of the coil between the towers of each individual coil Fig. 3. Secondary resistance should be 7,000 to 15,800 ohms. Replace the coil if resistance is not within tolerance. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3247 Ignition Coil: Service and Repair Fig. 11 Electronic Ignition Coil Pack The electronic ignition coil pack attaches to the cylinder head cover Fig. 11. REMOVAL 1. Disconnect engine harness connector from coil pack. 2. Remove coil pack mounting nuts. 3. Remove ignition cables. Always twist the spark plug boots to break the seal with the plug and pull straight back on the boot. 4. Remove coil. 5. Transfer spark plug cables to new coil pack. The coil pack towers and cables are numbered with the cylinder identification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor Torque 90 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 3251 Knock Sensor: Locations Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 15 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 15. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increase, the knock sensor output voltage also increases. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 3254 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code NAME OF CODE: Knock Sensor Circuit WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The knock sensor circuit voltage (cavity 27) falls below a minimum value at idle or deceleration. The minimum value is from a look-up table internal to the Powertrain Control Module (PCM) and is based on engine RPM. The trouble code also sets if the sensor output is above 5.0 volts. THEORY OF OPERATION: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezo-electric discs, producing an electrical signal. The signal is used by PCM cavity 27 to adjust ignition timing to eliminate the knock condition. POSSIBLE CAUSES: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Page 3255 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. RMS voltage starts at about 20mVac -- at about 700 rpm - and increases to approximately 600 mVac -- at 5,000 rpm. If the output falls outside of this range a DTC will be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Page 3256 Knock Sensor: Service and Repair Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. REMOVAL 1. Disconnect electrical connector from knock sensor Fig. 12. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3264 Camshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Camshaft Sensor Pick Up Bolts ..................................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3265 Camshaft Position Sensor: Locations Crank Shaft Position Sensor Camshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3266 Cam Shaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3267 Camshaft Position Sensor: Description and Operation Fig. 3 Camshaft Position Sensor 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. The sensor also acts as a thrust plate to control camshaft end play. Fig. 4 Target Magnet--Typical Fig. 5 Target Magnet Polarity Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3268 OPERATION The camshaft position sensor attaches to the rear of the cylinder head Fig. 4. A target magnet attaches to the rear of the camshaft and indexes to the correct position. The target magnet has four different poles arranged in an asymmetrical pattern. As the target magnet rotates, the camshaft position sensor senses the change in polarity Fig. 5. The sensor input switches from high (5 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. The sensor output switches low when the south pole of the target magnet passes underneath. The camshaft position sensor is mounted to the rear of the cylinder head. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3269 Camshaft Position Sensor: Service and Repair Fig. 6 Camshaft Position Sensor Location Fig. 7 Target Magnet Removal Fig. 8 Target Magnet Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head Fig. 6. REMOVAL 1. Disconnect the filtered air tube from the throttle body and air cleaner housing. 2. Remove air cleaner inlet tube. 3. Disconnect electrical connectors from engine coolant sensor and camshaft position sensor. 4. Remove camshaft position sensor mounting screws. Remove sensor. 5. Loosen screw attaching target magnet to rear of camshaft Fig. 7. NOTE: The target magnet has two locating dowels that fit into machined locating holes in end of the camshaft Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3270 INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Attach electrical connectors to coolant temperature sensor and camshaft position sensor. 4. Install air cleaner inlet tube and filtered air tube -- if applicable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3275 Crankshaft Position Sensor: Mechanical Specifications Sensor Screw Tightening Torque 105 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3276 Crankshaft Position Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3277 Crankshaft Position Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3278 Crankshaft Position Sensor: Description and Operation Fig 8 Timing Reference Notches Fig. 6 Timing Reference Notches Fig 9 Crankshaft Position Sensor OPERATION The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The second crankshaft counter-weight has machined into it two sets of four timing reference notches including a 60° signature notch Fig. 6. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). The notches generate pulses from high to low in the crankshaft position sensor output voltage. When a metal portion of the counterweight aligns with the crankshaft position sensor, the sensor output voltage goes low (less than 0.5 volts). When a notch aligns with the sensor, voltage goes high (5.0 volts). As a group of notches pass under the sensor, the output voltage switches from low (metal) to high (notch) then back to low. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3279 If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. The faster the engine is operating, the smaller the pulse-width on the oscilloscope. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches, the first notch represents 69° Before Top Dead Center (BTDC). The second notch represents 49° BTDC. The third notch represents 29°. The last notch in each set represents 9° Before Top Dead Center (TDC). The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Fig. 8 Crankshaft Position Sensor The crankshaft position sensor attaches to the cowl side of the engine block. It is located between the main bearing cap/bed plate assembly and block behind the power steering pump Fig. 8. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3280 Crankshaft Position Sensor: Service and Repair Fig. 9 Crankshaft Position Sensor The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter Fig. 9. 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3290 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3291 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 (L4-2.4L VIN X (1998)) 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 3292 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 (L4-2.4L VIN X (1998)) 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 3293 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 (L4-2.4L VIN X (1998)) 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 3294 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 (L4-2.4L VIN X (1998)) 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 3295 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 (L4-2.4L VIN X (1998)) 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 3296 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 (L4-2.4L VIN X (1998)) 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 3297 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 (L4-2.4L VIN X (1998)) 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 3298 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 (L4-2.4L VIN X (1998)) 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 3299 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 (L4-2.4L VIN X (1998)) 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 3300 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 (L4-2.4L VIN X (1998)) 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 3301 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3307 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3308 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 (L4-2.4L VIN X (1998)) 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 3309 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 (L4-2.4L VIN X (1998)) 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 3310 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 (L4-2.4L VIN X (1998)) 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 3311 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 (L4-2.4L VIN X (1998)) 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 3312 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 (L4-2.4L VIN X (1998)) 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 3313 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 (L4-2.4L VIN X (1998)) 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 3314 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 (L4-2.4L VIN X (1998)) 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 3315 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 (L4-2.4L VIN X (1998)) 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 3316 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 (L4-2.4L VIN X (1998)) 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 3317 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 (L4-2.4L VIN X (1998)) 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 3318 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3319 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3320 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3321 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Sensor Torque 90 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3325 Knock Sensor: Locations Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 15 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 15. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increase, the knock sensor output voltage also increases. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 3328 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code NAME OF CODE: Knock Sensor Circuit WHEN MONITORED: With the ignition ON and the engine running. SET CONDITION: The knock sensor circuit voltage (cavity 27) falls below a minimum value at idle or deceleration. The minimum value is from a look-up table internal to the Powertrain Control Module (PCM) and is based on engine RPM. The trouble code also sets if the sensor output is above 5.0 volts. THEORY OF OPERATION: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezo-electric discs, producing an electrical signal. The signal is used by PCM cavity 27 to adjust ignition timing to eliminate the knock condition. POSSIBLE CAUSES: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 3329 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock sensor generates an AC voltage whose amplitude increases with the increase of engine knock. The knock sensor can be tested with a digital voltmeter. RMS voltage starts at about 20mVac -- at about 700 rpm - and increases to approximately 600 mVac -- at 5,000 rpm. If the output falls outside of this range a DTC will be set. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 3330 Knock Sensor: Service and Repair Fig. 12 Knock Sensor The knock sensor threads into the side of the cylinder block in front of the starter Fig. 12. REMOVAL 1. Disconnect electrical connector from knock sensor Fig. 12. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................... 1.21-1.34 mm (0.048-0.53 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3334 Spark Plug: Application and ID Plug Type ............................................................................................................................................ ................................................................... RC12YC5 Thread size ..................................................... ................................................................................................................................................. (14mm) 3/4 in. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3335 Spark Plug: Description and Operation Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3338 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3339 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3340 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3341 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3342 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3343 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3344 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 ^ 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 0.033 - 0.038 in. - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3345 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3346 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap 0.048 to 0.053 in Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3347 Spark Plug: Service and Repair SPARK PLUG SERVICE Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 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. Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: Special care should be used when installing spark plugs in the cylinder head spark plug wells. Re sure the plugs do not drop into the wells, damage to the electrodes can occur. 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SEE Testing and Inspection/Spark Plug Condition. Fig. 4 Setting Spark Plug Electrode Gap SPARK PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground electrode Fig. 4. SPARK PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. CAUTION: Over tightening can cause distortion and change spark plug gap. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. SPARK PLUG TUBES Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3348 The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. For engine information, SEE Engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3355 Transmission Solenoid Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) 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 3362 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) 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 3363 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3374 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3375 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3381 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3382 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3385 Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3386 Power Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3387 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3388 Fuse Block PCM Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3389 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3392 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3395 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 (L4-2.4L VIN X (1998)) 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 3396 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 (L4-2.4L VIN X (1998)) 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 3397 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 (L4-2.4L VIN X (1998)) 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 3398 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 (L4-2.4L VIN X (1998)) 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 3399 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 (L4-2.4L VIN X (1998)) 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 3400 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 (L4-2.4L VIN X (1998)) 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 3401 - 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 (L4-2.4L VIN X (1998)) 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 3402 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 (L4-2.4L VIN X (1998)) 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 3403 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 (L4-2.4L VIN X (1998)) 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 3404 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3405 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 (L4-2.4L VIN X (1998)) 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 3406 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 (L4-2.4L VIN X (1998)) 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 3407 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 (L4-2.4L VIN X (1998)) 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 3408 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3411 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 (L4-2.4L VIN X (1998)) 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 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3415 Transmission Control Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch Autostick Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch > Page 3422 Transmission Range Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3431 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 (L4-2.4L VIN X (1998)) 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 3432 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 (L4-2.4L VIN X (1998)) 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 3433 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3439 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 (L4-2.4L VIN X (1998)) 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 3440 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3445 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 (L4-2.4L VIN X (1998)) 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 3446 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 (L4-2.4L VIN X (1998)) 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 3447 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3453 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 (L4-2.4L VIN X (1998)) 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 3454 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 (L4-2.4L VIN X (1998)) 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 3455 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3458 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3459 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3460 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 (L4-2.4L VIN X (1998)) 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 3461 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 (L4-2.4L VIN X (1998)) 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 3462 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3471 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3476 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 (L4-2.4L VIN X (1998)) 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 3477 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 (L4-2.4L VIN X (1998)) 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 3478 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3484 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3489 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 (L4-2.4L VIN X (1998)) 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 3490 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 (L4-2.4L VIN X (1998)) 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 3491 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 (L4-2.4L VIN X (1998)) 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 3492 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3493 Input / Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3496 Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3497 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 803 > Feb > 99 > Recall - Reprogram PCM Technical Service Bulletin # 803 Date: 990201 Recall - Reprogram PCM February 1999 California Emissions Recall No. 803 Reprogram Powertrain Control Module Models 1998 (JA) Dodge Stratus and Plymouth Breeze 1998 (JX) Chrysler Sebring Convertible Note: This recall applies to vehicles equipped with a 2.4L engine ("X" in the 8th VIN position) and a California emissions control system (sales code NAE) built through October 16, 1997 (MDH 1016XX). Subject The On-Board Diagnostic (OBD) system on about 3,900 of the above vehicles does not operate the evaporative emissions purge system monitor. California Air Resources Board (CARB) regulations require a purge system monitor as part of the OBD system. Repair To repair this condition, the Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08803181 0.2 hours Reprogram Powertrain Control Module 08803182 0.5 hours Add the cost of the labels 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 Applicable Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3509 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD803". 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 notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1176 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. 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. 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. B. Install Authorized Software Update Label Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3510 Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Type or print (with a ballpoint pen) the information on the Authorized Modifications Label and attach the label near the VECI label (Figure 2). D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: It has been determined that some 1998 Chrysler Sebring Convertible, Dodge Stratus and Plymouth Breeze vehicles equipped with a 2.4L engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) does not operate the evaporative emissions purge system monitor. California Air Resources Board (CARB) regulations require an evaporative emissions purge system monitor as part of the OBD system. The OBD system will not illuminate the "Check Engine" light if an evaporative emissions purge system component fails. This could result in hydrocarbon (HC) levels above the allowable limits that were established to protect the public health from the dangers of air pollution. HC emissions consist of unburned fuel that is released into the atmosphere. HC in combination with NOx in the presence of sunlight can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3511 ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done.. The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed.. State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 24-15-98 > Nov > 98 > A/C System - Performance Complaints/Compressor Failure Technical Service Bulletin # 24-15-98 Date: 981120 A/C System - Performance Complaints/Compressor Failure NO: 24-15-98 GROUP: Air Conditioning DATE: Nov. 20, 1998 SUBJECT: A/C System Performance MODELS: 1998 - 1999 (JA) Breeze/Cirrus/Stratus 1998 - 1999 (JX) Sebring Convertible NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L OR 2.5L ENGINE. SYMPTOM/CONDITION: A/C performance complaints and/or A/C compressor failure (seized) in high ambient temperatures (90°+ F). This condition can be aggravated by start and stop city driving and/or extended periods of idling with the A/C running. DIAGNOSIS: If the A/C compressor is failed, repair/replace as described on page 24-14 of the 1998 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-8121) or page 24-14 of the 1998 Sebring Convertible Service Manual (Publication No. 81-270-8122) before proceeding. If A/C performance at high ambient temperature is unsatisfactory, even if it passes the Performance Test Procedure as described on page 24-5 of the 1998 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-8121) or 1998 Sebring Convertible Service Manual (Publication No. 81-270-8122), continue with the 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 with the Repair Procedure. NOTE: FOR MAXIMUM A/C SYSTEM PERFORMANCE ON 1998 M.Y. VEHICLES THIS BULLETIN SHOULD BE PERFORMED IN CONJUNCTION WITH TSB 24-04-98. 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 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 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 1173 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-98 PCM, Reprogram 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 24-15-98 > Nov > 98 > A/C System - Performance Complaints/Compressor Failure > Page 3517 Repair Procedure 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. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3522 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 (L4-2.4L VIN X (1998)) 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 3523 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 (L4-2.4L VIN X (1998)) 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 3524 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3530 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 (L4-2.4L VIN X (1998)) 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 3531 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 (L4-2.4L VIN X (1998)) 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 3532 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 (L4-2.4L VIN X (1998)) 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 3533 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 (L4-2.4L VIN X (1998)) 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 3534 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 (L4-2.4L VIN X (1998)) 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 3535 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 (L4-2.4L VIN X (1998)) 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 3536 ^ 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 (L4-2.4L VIN X (1998)) 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 3537 ^ 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 (L4-2.4L VIN X (1998)) 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 3538 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3539 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3540 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3541 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 (L4-2.4L VIN X (1998)) 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 3542 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 (L4-2.4L VIN X (1998)) 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 3543 ^ 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 (L4-2.4L VIN X (1998)) 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 3544 ^ 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 (L4-2.4L VIN X (1998)) 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 3545 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 (L4-2.4L VIN X (1998)) 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 3546 ^ 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 (L4-2.4L VIN X (1998)) 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 3547 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 (L4-2.4L VIN X (1998)) 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 3548 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 (L4-2.4L VIN X (1998)) 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: > 803 > Feb > 99 > Recall - Reprogram PCM Technical Service Bulletin # 803 Date: 990201 Recall - Reprogram PCM February 1999 California Emissions Recall No. 803 Reprogram Powertrain Control Module Models 1998 (JA) Dodge Stratus and Plymouth Breeze 1998 (JX) Chrysler Sebring Convertible Note: This recall applies to vehicles equipped with a 2.4L engine ("X" in the 8th VIN position) and a California emissions control system (sales code NAE) built through October 16, 1997 (MDH 1016XX). Subject The On-Board Diagnostic (OBD) system on about 3,900 of the above vehicles does not operate the evaporative emissions purge system monitor. California Air Resources Board (CARB) regulations require a purge system monitor as part of the OBD system. Repair To repair this condition, the Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08803181 0.2 hours Reprogram Powertrain Control Module 08803182 0.5 hours Add the cost of the labels 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 Applicable Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3553 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD803". 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 notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1176 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. 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. 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. B. Install Authorized Software Update Label Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3554 Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Type or print (with a ballpoint pen) the information on the Authorized Modifications Label and attach the label near the VECI label (Figure 2). D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: It has been determined that some 1998 Chrysler Sebring Convertible, Dodge Stratus and Plymouth Breeze vehicles equipped with a 2.4L engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) does not operate the evaporative emissions purge system monitor. California Air Resources Board (CARB) regulations require an evaporative emissions purge system monitor as part of the OBD system. The OBD system will not illuminate the "Check Engine" light if an evaporative emissions purge system component fails. This could result in hydrocarbon (HC) levels above the allowable limits that were established to protect the public health from the dangers of air pollution. HC emissions consist of unburned fuel that is released into the atmosphere. HC in combination with NOx in the presence of sunlight can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3555 ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done.. The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed.. State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 24-15-98 > Nov > 98 > A/C System - Performance Complaints/Compressor Failure Technical Service Bulletin # 24-15-98 Date: 981120 A/C System - Performance Complaints/Compressor Failure NO: 24-15-98 GROUP: Air Conditioning DATE: Nov. 20, 1998 SUBJECT: A/C System Performance MODELS: 1998 - 1999 (JA) Breeze/Cirrus/Stratus 1998 - 1999 (JX) Sebring Convertible NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L OR 2.5L ENGINE. SYMPTOM/CONDITION: A/C performance complaints and/or A/C compressor failure (seized) in high ambient temperatures (90°+ F). This condition can be aggravated by start and stop city driving and/or extended periods of idling with the A/C running. DIAGNOSIS: If the A/C compressor is failed, repair/replace as described on page 24-14 of the 1998 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-8121) or page 24-14 of the 1998 Sebring Convertible Service Manual (Publication No. 81-270-8122) before proceeding. If A/C performance at high ambient temperature is unsatisfactory, even if it passes the Performance Test Procedure as described on page 24-5 of the 1998 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-8121) or 1998 Sebring Convertible Service Manual (Publication No. 81-270-8122), continue with the 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 with the Repair Procedure. NOTE: FOR MAXIMUM A/C SYSTEM PERFORMANCE ON 1998 M.Y. VEHICLES THIS BULLETIN SHOULD BE PERFORMED IN CONJUNCTION WITH TSB 24-04-98. 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 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 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 1173 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-98 PCM, Reprogram 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 24-15-98 > Nov > 98 > A/C System - Performance Complaints/Compressor Failure > Page 3560 Repair Procedure 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. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3565 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 (L4-2.4L VIN X (1998)) 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 3566 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 (L4-2.4L VIN X (1998)) 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 3567 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3573 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 (L4-2.4L VIN X (1998)) 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 3574 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 (L4-2.4L VIN X (1998)) 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 3575 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 (L4-2.4L VIN X (1998)) 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 3576 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 (L4-2.4L VIN X (1998)) 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 3577 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 (L4-2.4L VIN X (1998)) 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 3578 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 (L4-2.4L VIN X (1998)) 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 3579 ^ 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 (L4-2.4L VIN X (1998)) 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 3580 ^ 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 (L4-2.4L VIN X (1998)) 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 3581 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3582 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3583 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3584 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 (L4-2.4L VIN X (1998)) 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 3585 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 (L4-2.4L VIN X (1998)) 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 3586 ^ 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 (L4-2.4L VIN X (1998)) 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 3587 ^ 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 (L4-2.4L VIN X (1998)) 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 3588 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 (L4-2.4L VIN X (1998)) 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 3589 ^ 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 (L4-2.4L VIN X (1998)) 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 3590 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 (L4-2.4L VIN X (1998)) 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 3591 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 (L4-2.4L VIN X (1998)) 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: > 24-15-98 > Nov > 98 > A/C System - Performance Complaints/Compressor Failure Technical Service Bulletin # 24-15-98 Date: 981120 A/C System - Performance Complaints/Compressor Failure NO: 24-15-98 GROUP: Air Conditioning DATE: Nov. 20, 1998 SUBJECT: A/C System Performance MODELS: 1998 - 1999 (JA) Breeze/Cirrus/Stratus 1998 - 1999 (JX) Sebring Convertible NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L OR 2.5L ENGINE. SYMPTOM/CONDITION: A/C performance complaints and/or A/C compressor failure (seized) in high ambient temperatures (90°+ F). This condition can be aggravated by start and stop city driving and/or extended periods of idling with the A/C running. DIAGNOSIS: If the A/C compressor is failed, repair/replace as described on page 24-14 of the 1998 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-8121) or page 24-14 of the 1998 Sebring Convertible Service Manual (Publication No. 81-270-8122) before proceeding. If A/C performance at high ambient temperature is unsatisfactory, even if it passes the Performance Test Procedure as described on page 24-5 of the 1998 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-8121) or 1998 Sebring Convertible Service Manual (Publication No. 81-270-8122), continue with the 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 with the Repair Procedure. NOTE: FOR MAXIMUM A/C SYSTEM PERFORMANCE ON 1998 M.Y. VEHICLES THIS BULLETIN SHOULD BE PERFORMED IN CONJUNCTION WITH TSB 24-04-98. 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 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 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 1173 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-40-98 PCM, Reprogram 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 24-15-98 > Nov > 98 > A/C System - Performance Complaints/Compressor Failure > Page 3596 Repair Procedure 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. 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 (L4-2.4L VIN X (1998)) 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: > 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 (L4-2.4L VIN X (1998)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3601 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 (L4-2.4L VIN X (1998)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3602 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 (L4-2.4L VIN X (1998)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3603 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 (L4-2.4L VIN X (1998)) 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 3609 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 (L4-2.4L VIN X (1998)) 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 3610 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 (L4-2.4L VIN X (1998)) 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 3611 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 (L4-2.4L VIN X (1998)) 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 3612 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 (L4-2.4L VIN X (1998)) 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 3613 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 (L4-2.4L VIN X (1998)) 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 3614 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 (L4-2.4L VIN X (1998)) 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 3615 ^ 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 (L4-2.4L VIN X (1998)) 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 3616 ^ 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 (L4-2.4L VIN X (1998)) 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 3617 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3618 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3619 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3620 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 (L4-2.4L VIN X (1998)) 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 3621 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 (L4-2.4L VIN X (1998)) 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 3622 ^ 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 (L4-2.4L VIN X (1998)) 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 3623 ^ 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 (L4-2.4L VIN X (1998)) 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 3624 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 (L4-2.4L VIN X (1998)) 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 3625 ^ 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 (L4-2.4L VIN X (1998)) 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 3626 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 (L4-2.4L VIN X (1998)) 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 3627 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 (L4-2.4L VIN X (1998)) 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: > 803 > Feb > 99 > Recall - Reprogram PCM Technical Service Bulletin # 803 Date: 990201 Recall - Reprogram PCM February 1999 California Emissions Recall No. 803 Reprogram Powertrain Control Module Models 1998 (JA) Dodge Stratus and Plymouth Breeze 1998 (JX) Chrysler Sebring Convertible Note: This recall applies to vehicles equipped with a 2.4L engine ("X" in the 8th VIN position) and a California emissions control system (sales code NAE) built through October 16, 1997 (MDH 1016XX). Subject The On-Board Diagnostic (OBD) system on about 3,900 of the above vehicles does not operate the evaporative emissions purge system monitor. California Air Resources Board (CARB) regulations require a purge system monitor as part of the OBD system. Repair To repair this condition, the Powertrain Control Module (PCM) must be reprogrammed (flashed). Parts Information Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Authorized Software Update labels and Authorized Modifications labels to service about 25% of those vehicles. Additional labels may be ordered as needed. Each vehicle requires application of the following labels: Part Number Description 04669020 Authorized Software Update Label 04275086 Authorized Modifications Label Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08803181 0.2 hours Reprogram Powertrain Control Module 08803182 0.5 hours Add the cost of the labels 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 Applicable Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3632 DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD803". 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 notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1176 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III UPDATE on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III that will allow the DRB III to obtain the current part number of the PCM. 8. 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. 9. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. B. Install Authorized Software Update Label Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3633 Fig. 1 Type or print (with a ballpoint pen) the necessary information on the "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the label. C. Install the Authorized Modifications Label Fig. 2 Type or print (with a ballpoint pen) the information on the Authorized Modifications Label and attach the label near the VECI label (Figure 2). D. Complete Proof of Correction Form For California Residents This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear DaimlerChrysler Vehicle Owner: It has been determined that some 1998 Chrysler Sebring Convertible, Dodge Stratus and Plymouth Breeze vehicles equipped with a 2.4L engine, may be in violation of California Emissions Regulations. The problem is... The On-Board Diagnostic (OBD) system on your vehicle (identified on the enclosed form) does not operate the evaporative emissions purge system monitor. California Air Resources Board (CARB) regulations require an evaporative emissions purge system monitor as part of the OBD system. The OBD system will not illuminate the "Check Engine" light if an evaporative emissions purge system component fails. This could result in hydrocarbon (HC) levels above the allowable limits that were established to protect the public health from the dangers of air pollution. HC emissions consist of unburned fuel that is released into the atmosphere. HC in combination with NOx in the presence of sunlight can cause the formation of ozone. These pollutants are the primary components of smog. What DaimlerChrysler and your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram your vehicle's powertrain control module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer right away to schedule a service appointment. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 803 > Feb > 99 > Recall - Reprogram PCM > Page 3634 ^ Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you live in California and don't get this done.. The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed.. State of California regulations require DaimlerChrysler to provide the Department of Motor Vehicles with a record of all vehicles that have not had the recall service performed. If you live in the state of California and your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and your continued satisfaction with our products. Thank you for your attention to this important matter. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3641 Transmission Solenoid Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3647 Transmission Solenoid Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions Clutch: Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions NUMBER: 26-11-97H GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to Test 53 - Repairing speed ratio in third gear Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 3652 294 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 3653 298 Revision to the front pump inspection procedures Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 3654 380 Revision to the low reverse reaction plate specifications Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 3655 413 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch Pack Clearances Clutch: Specifications Clutch Pack Clearances 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Clutch Pack Clearances > Page 3658 Clutch: Specifications Low Reverse Clutch Clutch Retainer .................................................................................................................................... .................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3661 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3662 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3663 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 3664 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3673 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3674 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3680 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3681 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3684 Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3685 Power Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3686 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3687 Fuse Block PCM Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 3688 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 3691 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3694 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3695 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3696 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3697 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3698 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3699 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3700 - 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3701 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3702 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3703 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3704 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3705 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3706 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 3707 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > General Information > Page 3710 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations Data Link Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations > Page 3714 Data Link Connector (16 - Way) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3733 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3734 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3735 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3736 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3737 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Service Fill Capacity ............................................................................................................................ ............................................................. 3.8L (4.0 Qt) Dry fill with empty torque converter .................. ............................................................................................................................................... 8.6L (9.1 Qt) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3740 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 3743 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 3744 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 3749 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Hose Clamps ....................................................................................................................................... .................................................... 2 Nm (18 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 3753 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3765 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3766 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3767 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3773 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 (L4-2.4L VIN X (1998)) 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 3774 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 (L4-2.4L VIN X (1998)) 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 3775 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 (L4-2.4L VIN X (1998)) 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: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions Fluid Pump: All Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions NUMBER: 26-11-97H GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to Test 53 - Repairing speed ratio in third gear Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 3780 294 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 3781 298 Revision to the front pump inspection procedures Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 3782 380 Revision to the low reverse reaction plate specifications Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 3783 413 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions Fluid Pump: All Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions NUMBER: 26-11-97H GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to Test 53 - Repairing speed ratio in third gear Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 3789 294 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 3790 298 Revision to the front pump inspection procedures Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 3791 380 Revision to the low reverse reaction plate specifications Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 3792 413 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 3793 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 3794 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 3795 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 (L4-2.4L VIN X (1998)) 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. Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) 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 3801 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) 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 3802 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 3807 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 3808 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3818 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3819 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3825 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 3826 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3829 Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3830 Power Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3831 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3832 Fuse Block PCM Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3833 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3836 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3839 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 (L4-2.4L VIN X (1998)) 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 3840 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 (L4-2.4L VIN X (1998)) 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 3841 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 (L4-2.4L VIN X (1998)) 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 3842 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 (L4-2.4L VIN X (1998)) 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 3843 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 (L4-2.4L VIN X (1998)) 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 3844 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 (L4-2.4L VIN X (1998)) 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 3845 - 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 (L4-2.4L VIN X (1998)) 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 3846 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 (L4-2.4L VIN X (1998)) 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 3847 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 (L4-2.4L VIN X (1998)) 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 3848 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3849 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 (L4-2.4L VIN X (1998)) 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 3850 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 (L4-2.4L VIN X (1998)) 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 3851 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 (L4-2.4L VIN X (1998)) 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 3852 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3855 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 3859 Transmission Control Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3868 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 (L4-2.4L VIN X (1998)) 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 3869 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 (L4-2.4L VIN X (1998)) 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 3870 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3876 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3881 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 (L4-2.4L VIN X (1998)) 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 3882 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 (L4-2.4L VIN X (1998)) 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 3883 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3889 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 (L4-2.4L VIN X (1998)) 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 3890 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 (L4-2.4L VIN X (1998)) 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 3891 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 (L4-2.4L VIN X (1998)) 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 3892 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 (L4-2.4L VIN X (1998)) 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 3893 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 (L4-2.4L VIN X (1998)) 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 3894 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (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 (L4-2.4L VIN X (1998)) 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 3895 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 (L4-2.4L VIN X (1998)) 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 3896 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 (L4-2.4L VIN X (1998)) 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 3897 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Page 3898 Seals and Gaskets: Service and Repair Remove Oil Pump Seal Install Oil Pump Seal Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch Autostick Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch > Page 3904 Transmission Range Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3913 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 (L4-2.4L VIN X (1998)) 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 3914 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 (L4-2.4L VIN X (1998)) 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 3915 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3921 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 (L4-2.4L VIN X (1998)) 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 3922 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3927 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 (L4-2.4L VIN X (1998)) 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 3928 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 (L4-2.4L VIN X (1998)) 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 3929 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3935 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3936 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 (L4-2.4L VIN X (1998)) 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 3937 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3940 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3941 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3942 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3943 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3944 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3953 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3958 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 (L4-2.4L VIN X (1998)) 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 3959 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 (L4-2.4L VIN X (1998)) 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 3960 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3966 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3971 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 (L4-2.4L VIN X (1998)) 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 3972 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 (L4-2.4L VIN X (1998)) 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 3973 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 (L4-2.4L VIN X (1998)) 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 3974 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 3975 Input / Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 3978 Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 3979 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Service and Repair 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 3990 Transmission Solenoid Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 3999 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4000 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4001 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4002 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4003 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4004 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4005 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4006 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4007 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4008 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4009 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4010 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4016 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4017 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4018 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4019 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4020 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4021 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4022 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4023 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4024 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4025 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4026 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > C45 > Jun > 04 > Recall - A/T Shifter Ignition/Park Interlock Defect > Page 4027 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Page 4028 Shifter A/T: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Remove the gearshift knob set screw and knob. 3. Remove console assembly. 4. Using a flat blade pry tool, remove the shifter cable end from the gearshift mechanism. 5. Pry the cable retaining clip up and off of the gearshift mechanism. Remove the gearshift cable from the gearshift mechanism. 6. Pry up the adjuster lock on the shifter / ignition interlock cable. Unsnap the shifter / ignition interlock cable end fitting from the groove in the gearshift mechanism. Remove the cable core end from the plastic cam of the shifter mechanism. 7. Remove the nuts at the base of the gearshift mechanism. Remove the shifter mechanism. INSTALLATION For installation, reverse removal steps. Tighten the nuts at the base of the gearshift mechanism to 17 Nm (150 inch lbs.). Refer to Cable Adjustment for cable adjustment procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4036 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4037 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Description and Operation > Front Sun Gear Assembly > Page 4042 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4046 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4050 Transmission Control Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4054 Transmission Cooler: Description and Operation GENERAL INFORMATION Oil coolers are internal oil to coolant type, mounted in the radiator left tank. RUBBER LINES Rubber oil lines feed the oil cooler and the automatic transmission. Use only approved transmission oil cooler hose. Since these are molded to fit space available, molded hoses are recommended. Tighten Oil Cooler Hose Clamps to 2 Nm (18 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4055 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 (L4-2.4L VIN X (1998)) 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. Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 4060 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 4061 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch Autostick Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch > Page 4066 Transmission Range Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4075 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 (L4-2.4L VIN X (1998)) 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 4076 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 (L4-2.4L VIN X (1998)) 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 4077 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4083 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 (L4-2.4L VIN X (1998)) 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 4084 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4089 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 (L4-2.4L VIN X (1998)) 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 4090 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 (L4-2.4L VIN X (1998)) 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 4091 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4097 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 (L4-2.4L VIN X (1998)) 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 4098 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4099 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4102 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4103 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4104 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4105 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4106 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4118 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4123 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 (L4-2.4L VIN X (1998)) 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 4124 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 (L4-2.4L VIN X (1998)) 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 4125 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4131 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4136 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 (L4-2.4L VIN X (1998)) 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 4137 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 (L4-2.4L VIN X (1998)) 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 4138 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4139 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4140 Input / Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 4143 Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4144 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4156 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 (L4-2.4L VIN X (1998)) 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 4157 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 (L4-2.4L VIN X (1998)) 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 4158 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4164 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 (L4-2.4L VIN X (1998)) 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 4165 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 (L4-2.4L VIN X (1998)) 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 4166 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4167 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4168 A604 (41TE) 4 Speed Transaxle Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4169 A604 (41TE) 4 Speed Transaxle Solenoid Pack Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4172 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4173 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4174 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4175 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4176 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4177 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4178 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 4179 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4182 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4183 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4184 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4185 Valve Body: Service and Repair Solenoid Assembly Replacement REMOVAL Input Speed Sensor Removed Remove Sound Cover Remove Attaching Screws Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4186 Remove Solenoid Assembly INSTALLATION To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4187 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4188 2-4 Accumulator Plate TRS, Manual Shaft, And 2-4 Accumulator Valve Body Screws Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4189 Valve Body And Transfer Plate Transfer Plate And Separator Plate Ball Check Location Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4190 Springs And Valves Location Remove Or Install Dual Retainer Plate TC Limit Valve And Low/Reverse Switch Valve Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Adjustments > Page 4195 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation Axle Shaft: Description and Operation 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4205 Axle Shaft: Testing and Inspection VEHICLE 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4206 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 244 Nm (180 ft. lbs.).This will ensure that the hub bearing cannot loosen. Cottor Pin. But Lock And Spring Washer 1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle. Loosening Front Hub Retaining Nut 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4207 Caliper Guide Pin Attaching Bolts 5. Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts. Removing Disc Brake Caliper 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. Correctly Supported Brake Caliper 7. Support brake caliper/adapter assembly using a wire hook. Do not support assembly by the brake flex hose. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4208 8. Remove braking disc from front hub. Removing Tie Rod End Attaching Nut 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. Tie Rod End Removal From Steering Knuckle 10. Remove the tie rod end stud from steering knuckle arm, using remover, Special Tool MB-990635. Wheel Speed Sensor Cable Routing Bracket 11. If equipped with antilock brakes, remove the speed sensor cable routing bracket from the steering knuckle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4209 Lower Ball Joint To Steering Knuckle Attachment 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. Separating Ball Joint Stud From Steering Knuckle 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4210 Separating Steering Knuckle From Outer C/V Joint 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. Disengaging Inner Tripod Joint From Transaxle 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. Tripod Joint Removal From Transaxle Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4211 16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of 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 244 Nm (180 ft. lbs.). This will ensure that the hub bearing cannot loosen. 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. Outer C/V Joint Inspection 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. Steering Knuckle Installation On Outer C/V Joint 6. Slide driveshaft back into front hub. Then install steering knuckle onto the lower control arm ball joint stud. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4212 Lower Ball Joint To Steering Knuckle Attachment 7. Install the steering knuckle to ball joint stud castle nut. Tighten the castle nut to 95 Nm (70 ft. lbs.). Wheel Speed Sensor Cable Routing Bracket 8. If equipped with antilock brakes, install the speed sensor cable on the steering knuckle and securely tighten bolt. Installing Tie Rod End Nut Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4213 Torquing Tie Rod End Nut 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. Disc Brake Caliper Assembly Installation 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. Disc Brake Caliper Bolts Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4214 12. Install caliper assembly to steering knuckle guide pin bolt. Tighten caliper assembly bolts to 31 Nm (23 ft. lbs.). Install Washer And Hub Nut 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. Torquing Front Hub Nut 14. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 244 Nm (180 ft. lbs.). Spring Washer, Nut Lock And Cotter Pin Installation 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Description and Operation > Page 4215 Wheel Lug Torquing Sequence 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 (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement Constant Velocity Joint Boot: Service and Repair Inner Tripod Joint Sealing Boot Replacement REMOVAL 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 trunions to prevent the bearings from failing away. Spider Assembly Removal From Tripod Joint Housing 3. Slide the tripod joint housing off the spider assembly and the interconnecting shaft. Spider Assembly Retaining Snap Ring Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4220 Spider Assembly Removal From Inerconnecting 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. 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. Sealing Boot Installation On Interconnecting Shaft 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 (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4221 Spider Assembly Installation On Interconnecting Shaft Installing Spider Assembly On Interconnecting Shaft 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. Spider Assembly Retaining Snap Ring Installed 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4222 housing. Put the remaining amount into the sealing boot. Installing Tripod Hosing On Spider Assembly 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. Crimping Tool Installed On Sealing Boot Clamp Sealing Boot Retaining Clamp Installed 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 until jaws on tool are closed completely together, face to face. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4223 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. CAUTION: 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. CAUTION: 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. Trim Stick Inserted For Venting Tripod Joint 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 between soft rubber insert and tripod housing not 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. Crimping Tool Installed On Sealing Boot Clamp Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4224 - Place crimping tool C- 4975-A over bridge of clamp. Sealing Boot Retaining Clamp Installed - Tighten nut on crimping tool C- 4975-A 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. Clamping Tool Installed On Sealing Boot Clamp - Place prongs of clamp locking tool in the holes of the clamp. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4225 Sealing Boot Clamp Correctly Installed - Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp. 1. Install the driveshaft back on the vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4226 Constant Velocity Joint Boot: Service and Repair Outer CV Joint Bearing Shield 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. BEARING SHIELD REMOVAL FROM OUTER C/V JOINT 1. Clamp driveshaft in a vise by the interconnecting shaft. Removing Bearing Shield From Outer C/V Joint 2. Using a drift tap around the entire edge of the bearing shield until it is removed from the outer C/V Joint. BEARING SHIELD INSTALLATION ON OUTER C/V JOINT 1. Install bearing shield by hand on outer C/V Joint so that it is installed squarely on the C/V joint. Special Tools For Installing Bearing Shield 2. Position installer, Special Tool, C-4698-2 and handle, Special Tool, C-4698-1 on face of bearing shield. CAUTION: If bearing shield is not installed flush against the face of the outer C/V joint, interference with steering knuckle will occur when driveshaft is installed. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4227 Correctly Installed Bearing Shield 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 (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4228 Constant Velocity Joint Boot: Service and Repair Outer CV Joint Sealing Boot REMOVAL To remove outer C/V joint sealing boot from a driveshaft for replacement, the driveshaft assembly must be removed from the vehicle. 1. Remove driveshaft assembly requiring boot replacement from vehicle. Outer C/V Joint Seal Boot Clamps 2. Remove large boot clamp retaining C/V joint sealing boot to C/V joint housing and discard. Remove small clamp that retains outer C/V joint sealing boot, to interconnecting shaft and discard. Remove sealing boot from outer C/V joint housing and slide it down interconnecting shaft. 3. Wipe away grease to expose outer C/V joint and interconnecting shaft. Outer C/V Joint Removal From Interconnecting Shaft 4. Remove outer C/V joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer, sharply hit the end of the C/V joint housing to dislodge housing from internal circlip on interconnecting shaft. Then slide outer C/V joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4229 Circlip Removal From Interconnecting Shaft 5. Remove large circlip from the interconnecting shaft before attempting to remove outer C/V joint sealing boot. 6. Slide failed sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect outer C/V joint assembly and interconnecting joint 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. Sealing Boot Installation On Interconnecting Shaft INSTALLATION 1. Slide new sealing boot to interconnecting shaft retaining clamp onto interconnecting shaft. Slide the outer C/V joint assembly sealing boot onto the interconnecting shaft. 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. 2. Align splines on interconnecting shaft with splines on cross of outer C/V joint assembly and start outer C/V joint onto interconnecting shaft. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4230 Outer C/V Joint Installation On Interconnecting Shaft 3. Install outer C/V joint assembly onto interconnecting shaft by using a soft-faced hammer and tapping end of stub axle (with nut installed) until outer C/V joint is fully seated on interconnecting shaft. Outer C/V Joint Correctly Installed On Interconnecting Shaft 4. Outer C/V joint assembly must be installed on interconnecting shaft until cross of outer C/V joint assembly is seated against circlip on interconnecting shaft. 5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer C/V joint assembly housing. Put the remaining amount into the sealing boot. 6. Install outer C/V joint sealing boot to interconnecting shaft clamp evenly on sealing boot. Crimping Tool Installed On Sealing Boot Clamp Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4231 Sealing Boot Retaining Clamp Installed 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 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 outer C/V joint sealing boot into its retaining groove on outer C/V joint housing. Install sealing boot to outer C/V joint retaining clamp evenly on sealing boot. Crimping Tool Installed On Sealing Boot Clamp Sealing Boot Retaining Clamp Installed Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Sealing Boot Replacement > Page 4232 9. Clamp sealing boot onto outer C/V joint housing 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 until jaws on tool are closed completely together, face to face. 10. Install the driveshaft requiring boot replacement back on the vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4236 Wheel Bearing: Service Precautions CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result Do not use on pre-1998 model year vehicles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4237 Wheel Bearing: Description and Operation CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. 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 the diagnosis and testing section and the removal and installation section in this group of the service manual for the inspection and replacement of the rear wheel bearing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4238 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4239 Wheel Bearing: Service and Repair CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result Do not use on pre-1998 model year vehicles. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4240 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 129 Nm (95 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Driveshaft Nut ...................................................................................................................................... ................................................ 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications To Crankshaft Bolts ............................................................................................................................. ..................................................... 95 Nm (70 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) 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 4257 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) 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 4258 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .......................................................... 2.1L (4.4 Pints) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4264 Fluid - M/T: Fluid Type Specifications Transmission Fluid MOPAR type M.S. 9417 Manual Transaxle Fluid Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Page 4269 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4280 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4281 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4287 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4288 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4291 Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4292 Power Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4293 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4294 Fuse Block PCM Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4295 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4298 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4301 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 (L4-2.4L VIN X (1998)) 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 4302 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 (L4-2.4L VIN X (1998)) 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 4303 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 (L4-2.4L VIN X (1998)) 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 4304 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 (L4-2.4L VIN X (1998)) 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 4305 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 (L4-2.4L VIN X (1998)) 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 4306 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 (L4-2.4L VIN X (1998)) 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 4307 - 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 (L4-2.4L VIN X (1998)) 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 4308 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 (L4-2.4L VIN X (1998)) 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 4309 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 (L4-2.4L VIN X (1998)) 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 4310 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4311 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 (L4-2.4L VIN X (1998)) 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 4312 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 (L4-2.4L VIN X (1998)) 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 4313 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 (L4-2.4L VIN X (1998)) 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 4314 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4317 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 (L4-2.4L VIN X (1998)) 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 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4321 Transmission Control Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch Autostick Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch > Page 4328 Transmission Range Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4337 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 (L4-2.4L VIN X (1998)) 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 4338 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 (L4-2.4L VIN X (1998)) 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 4339 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4345 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 (L4-2.4L VIN X (1998)) 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 4346 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4351 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 (L4-2.4L VIN X (1998)) 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 4352 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 (L4-2.4L VIN X (1998)) 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 4353 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4359 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 (L4-2.4L VIN X (1998)) 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 4360 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 (L4-2.4L VIN X (1998)) 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 4361 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4364 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4365 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4366 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 (L4-2.4L VIN X (1998)) 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 4367 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 (L4-2.4L VIN X (1998)) 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 4368 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4377 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4382 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 (L4-2.4L VIN X (1998)) 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 4383 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 (L4-2.4L VIN X (1998)) 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 4384 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4390 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4395 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 (L4-2.4L VIN X (1998)) 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 4396 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 (L4-2.4L VIN X (1998)) 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 4397 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 (L4-2.4L VIN X (1998)) 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 4398 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4399 Input / Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4402 Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4403 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4413 Transmission Solenoid Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) 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 4420 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) 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 4421 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4432 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4433 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 (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: 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: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. 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. 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. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4439 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) 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 ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module 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 (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 & DRB III 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 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 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 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4440 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4443 Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4444 Power Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4445 Control Module: Locations Power Distribution Center Power Distribution Center 16 - Way Inline Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4446 Fuse Block PCM Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4447 BCM, Junction Block, Relays Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4450 Control Module: Diagrams Speed Proportional Steering Module Speed Proportional Steering Solenoid Speed Proportional Steering Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4453 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4454 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 (L4-2.4L VIN X (1998)) 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 4455 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 (L4-2.4L VIN X (1998)) 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 4456 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 (L4-2.4L VIN X (1998)) 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 4457 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 (L4-2.4L VIN X (1998)) 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 4458 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 (L4-2.4L VIN X (1998)) 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 4459 - 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 (L4-2.4L VIN X (1998)) 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 4460 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 (L4-2.4L VIN X (1998)) 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 4461 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 (L4-2.4L VIN X (1998)) 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 4462 MY. This sensor allows for accurate transaxle gear position identification. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4463 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 (L4-2.4L VIN X (1998)) 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 4464 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 (L4-2.4L VIN X (1998)) 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 4465 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 (L4-2.4L VIN X (1998)) 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 4466 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4469 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 (L4-2.4L VIN X (1998)) 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 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4473 Transmission Control Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch Autostick Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Autostick Switch > Page 4480 Transmission Range Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4489 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 (L4-2.4L VIN X (1998)) 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 4490 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 (L4-2.4L VIN X (1998)) 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 4491 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4497 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 (L4-2.4L VIN X (1998)) 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 4498 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4503 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 (L4-2.4L VIN X (1998)) 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 4504 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 (L4-2.4L VIN X (1998)) 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 4505 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4511 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 (L4-2.4L VIN X (1998)) 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 4512 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 (L4-2.4L VIN X (1998)) 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 4513 Transmission Position Switch/Sensor: Specifications Mounting Bolts ..................................................................................................................................... ................................................... 5 Nm (45 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4516 Transmission Position Switch/Sensor: Locations Sensor, Transmission Range Transmission Range Sensor Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4517 Transmission Range Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4518 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 (L4-2.4L VIN X (1998)) 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 4519 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 (L4-2.4L VIN X (1998)) 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 4520 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 4529 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4534 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4535 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4536 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4542 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4547 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4548 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4549 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4550 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4551 Input / Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4554 Output Speed Sensor Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4555 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The ABS system uses a yellow colored ABS Warning Lamp. The ABS warning lamp is located on the left side of the instrument panel, in the instrument cluster next to the tachometer. The purpose of the warning lamp is discussed in detail below. The ABS warning lamp will turn on when the Controller Antilock Brakes (CAB) detects a condition which results in a shutdown of ABS function or when the body controller does not receive C2D messages from the CAB. When the ignition key is turned to the on position, the ABS Warning Lamp is on until the CAB completes its self tests and turns the lamp off (approximately 4 seconds after the ignition switch is turned on). Under most conditions, when the ABS warning lamp is on, only the ABS function of the brake system is affected. The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on. The ABS warning lamp is controlled by the CAB and the body controller through a diode located in the wiring harness junction block. The junction block is located under the instrument panel to the left of the steering column. The CAB controls the lamp by directly grounding the circuit. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES Fuse Locations In Power Distribution Center The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center (PDC). The PDC is located on the drivers side of the engine compartment forward of the strut tower. ABS RELAYS On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will need to be replaced. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Description and Operation Brake Fluid Accumulator: Description and Operation There are two fluid accumulators in all hydraulic control units, one each for the primary and secondary hydraulic circuits. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This fluid is then used by the pump in the valve body to provide build pressure for the brake hydraulic system. Additionally on vehicles that are equipped with only ABS (non-traction control vehicles) there is a mini accumulator on the secondary hydraulic circuit which protects the master cylinder's seals during an ABS stop. There is also a noise damping chamber on the primary hydraulic circuit. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Diagrams Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Controller Antilock Brakes To HCU Mounting Bolts ............................................................................................................................. 2 Nm (17 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4576 Electronic Brake Control Module: Locations ICU Mounting Location Mounted on the crossmember over the steering gear on the right side. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4577 Controller Antilock Brakes Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4578 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock Brake System (ABS) amber warning lamp. The primary functions of the CAB are to: - detect wheel locking tendencies - control fluid pressure modulation to the brakes during antilock stop - monitor the system for proper operation - provide communication to the DRB while in diagnostic mode - store diagnostic information in non-volatile memory The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB for proper operation If the CAB detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp. If the antilock function is disabled, the system will revert to standard base brake system operation. CAB Inputs Include The Following: - ABS Warning Lamp - Diagnostic Communication - Four Wheel Speed Sensors - Ignition Switch - Fused B+ - Stop Lamp Switch CAB Outputs Include The Following: - ABS Warning Light Actuation - Voltage - Eight Valves - Diagnostic Communication - Body Controller Communication Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4579 Electronic Brake Control Module: Service and Repair REMOVE NOTE: To replace the Controller Antilock Brakes (CAB) on this vehicle, the Integrated Control Unit (ICU) and CAB need to be removed from the vehicle as a unit. The CAB can then be separated from the Hydraulic Control Unit (HCU). Do not attempt to replace the CAB with the ICU mounted in the vehicle. 1. Remove the ICU from the vehicle. Pump Motor To CAB Wiring Harness 2. Unplug the pump motor wiring harness from the CAB. CAB Attaching Bolts 3. Remove the 4 bolts attaching the CAB to the HCU. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 4580 Remove/Install CAB 4. Remove the CAB from the HCU. INSTALL 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU. 5. Bleed the base brakes and the ABS brakes hydraulic system. 6. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications To Mounting Bracket Bolts .................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Bracket To Crossmember Mounting Bolts .......................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information Teves Mark 20 ICU The hydraulic control unit (HCU) used with the Teves Mark 20 ABS is different from the HCU used on previous Chrysler products with ABS. The HCU used on this ABS system is part of the Integrated Control Unit (ICU). The HCU is part of what is referred to as the ICU because the HCU and the Controller Antilock Brakes (CAB) are combined (integrated) into one unit. This differs from previous Chrysler products with ABS, where the HCU and the CAB were separate components located in different areas of the vehicle. NOTE: The HCU and CAB used on a vehicle that is equipped with only ABS and on a vehicle that is equipped with ABS and traction control are different. The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is approximately 1 inch longer on the low pressure fluid accumulators side than a HCU for a vehicle that is equipped with only ABS. ICU Mounting Location The ICU is located on the passenger side of the vehicle, and is mounted to the front suspension crossmember. The ABS only ICU contains the following components for controlling the brake system hydraulic pressure during ABS braking: The CAB, eight valve solenoids, (four inlet valves and four outlet valves) fluid accumulators a pump, and an electric motor. CAUTION: No components of the ICU are serviceable. If any component that makes up the ICU is diagnosed as not functioning properly it MUST be replaced. The replaceable components of the ICU, are the HCU and the CAB. The mounting bracket is also replaceable as a separate component of the ICU. The remaining components of the ICU are not serviceable items. No attempt should ever be made to remove or service any individual components of the HCU. This is due to the concern of contamination entering the HCU while performing a service procedure. Also no attempt should ever be made to remove or service any individual components of the CAB. CAUTION: At no time when servicing the ICU should a 12 volt power source be applied to any electrical connector of the HCU or the CAB. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 4586 Hydraulic Control Assembly - Antilock Brakes: Description and Operation System Operation ICU Mounting Location General Information The Hydraulic Control Unit (HCU) contains the valve block assembly, two accumulators, and pump/motor assembly. The HCU is mounted on the crossmember over the steering gear on the right side. Valve Block Assembly The valve block assembly contains valves with four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position. During and antilock stop, these valves are cycled to maintain the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and further pressure increase. Then the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant. On JX and NS Bodies which are equipped with a traction control system, there are two additional valves that isolate the master cylinder and rear wheels. During a traction control situation the brakes are applied to reduce wheel slippage. Pump/Motor Assembly The pump/motor assembly provides the extra amount of fluid needed during antilock braking. The pump is supplied fluid that is released to the accumulators when the outlet valve is opened during and antilock stop. The pump is also used to drain the accumulator circuits after the antilock stop is complete. The pump is operated by an integral electric motor. This DC-type motor is controlled by the Control Antilock Brake (CAB). The CAB may turn on the pump motor when an antilock stop is detected. The pump continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor will run to drain the accumulators during the next drive off. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft secondary hydraulic circuit. In operation, one piston craw fluid from the accumulators. The opposing piston pumps fluid to the valve body solenoids. The CAB monitors the pump/motor operation internally. Accumulators The accumulators provide temporary fluid storage during an antilock stop and are drained by the pump/motor. Each of the diagonal circuits uses a 3cc. accumulator. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 4587 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Valves and Solenoids INLET VALVES AND SOLENOIDS There are four inlet solenoid valves, one for each wheel. In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle. When the ABS cycle has been completed the inlet solenoids will return to their released (open) position. OUTLET VALVES AND SOLENOIDS There are four outlet solenoid valves, one for each wheel. In the released position they are closed to allow for normal braking. In the actuated (open) position, they provide a fluid path from the wheel brakes of the vehicle to the ICU fluid accumulators and pump motor. The outlet valves are spring loaded in the released (closed) position during normal braking. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal Ground Cable Attachment At Strut Tower 1. Remove the remote ground cable from the ground stud 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 and installing the nut on the stud. This will prevent accidental grounding of the remote ground cable. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4590 4. Raise vehicle on jackstands or centered on a hoist. Right Side Splash Shield 5. Remove the splash shield from the right side of the engine compartment. 6. Remove entire exhaust system from the vehicle as a complete assembly using the following steps. a. Disconnect the oxygen sensor wiring harnesses from the vehicle wiring harness. b. Remove the ground strap between the frame and muffler at the muffler bracket. Exhaust Pipe Mounting To Exhaust Manifold c. Remove attaching bolts from exhaust pipe at exhaust manifold on engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4591 Exhaust System Support/Isolators Locations d. 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. e. Lower exhaust system as a complete assembly away from the underbody of the vehicle. HCU Heat Shield 7. Remove the heat shield for the Hydraulic Control Unit (HCU) from the HCU mounting bracket. 8. Using Mopar, Brake Parts Cleaner or an equivalent, thoroughly clean all surfaces of the HCU. Also, thoroughly clean all brake tube to HCU connections. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4592 Chassis Brake Tube Connections To HCU 9. Remove the 4 chassis brake tubes from the outlet ports on the HCU. Master Cylinder Brake Tube Connections To HCU 10. Remove the primary and secondary brake tubes coming from the master cylinder from the HCU inlet ports. HCU Mounting Bracket Front Bolt 11. Remove the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember. HCU Mounting Bracket Rear Bolts Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4593 12. Remove the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember. HCU To Bracket Mounting Bolt 13. Remove bolt attaching the side of the HCU to the mounting bracket. HCU To Bracket Mounting Bolt 14. Remove the 2 bolts attaching the top of the HCU to the mounting bracket. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 HCU connector when disconnected from the Controller Antilock Brakes (CAB). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4594 Unlocked CAB Connector 15. Disconnect the 25 way wiring harness connector from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it out from the connector as far as possible. This will unlock and raise the 25 way connector out of the socket on the CAB. HCU Remove And Install 16. Remove the HCU from its mounting bracket. Then remove the HCU from the vehicle by pulling it out through the area between the right drive shaft and frame rail. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4595 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Installation 1. Install the Hydraulic Control Unit (HCU) back in the vehicle and on its mounting bracket using the reverse order of its removal. HCU To Bracket Mounting Bolt HCU To Bracket Mounting Bolt 2. Install isolators, washers and attaching bolts, mounting the HCU to its mounting bracket. 3. Tighten the 3 HCU mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: Before installing the 25 way connector in the Controller Antilock Brakes (CAB) be sure that the seal is properly installed in the connector. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4596 Unlocked CAB Connector 4. Install the 25 way connector into the socket on the CAB. The connector is installed using the following procedure. Position the 25 way connector in the socket on the CAB and carefully push it down as far as it will go. When connector is fully seated into the CAB socket push in the connector lock as far as it will go. This will pull the 25 connector into the socket on the CAB and lock it in the installed position. HCU Mounting Bracket Rear Bolts 5. Install the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember. HCU Mounting Bracket Front Bolt Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4597 6. Install the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember. 7. Tighten the 3 bolts mounting the HCU mounting to the front suspension crossmember to a torque of 28 Nm (250 inch lbs.). Master Cylinder Brake Tube Connections To HCU 8. Install the primary and secondary brake tubes coming from the master cylinder in the HCU inlet ports. Chassis Brake Tube Connections To HCU 9. Install the 4 chassis brake tubes in the outlet ports on the HCU. Torquing Primary And Secondary Brake Tube Nut Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4598 Torquing Chassis Brake Tube Nuts 10. Using a crow foot tighten all of the brake tube nuts to a torque of 17 Nm (146 inch lbs.). HCU Heat Shield 11. Install the HCU heat shield on the HCU mounting bracket. Install and securely tighten the attaching bolt. 12. Install exhaust system in vehicle using the reverse steps of its removal. Right Side Splash Shield 13. Install right side engine compartment splash shield back on the vehicle. 14. Lower vehicle. 15. Remove brake pedal holding tool. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 4599 Ground Cable Attachment At Strut Tower 16. 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.). 17. Bleed the base brakes and the ABS brakes hydraulic system. 18. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Resistance 2,160 - 2,640 ohms Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 4604 Wheel Speed Sensor: Mechanical Specifications Total Indicator Run Out Allowed 0.006 in Front Rear Air Gap 0.007 - 0.072 in 0.015 - 0.059 in Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 4607 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 4610 Wheel Speed Sensor: Diagrams Rear Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 4611 Wheel Speed Sensor: Testing and Inspection CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tonewheels 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 Tonewheel Runout in the Specification Section in this section of the service manual for the tonewheel runout specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect tonewheels for looseness on their mounting surfaces. Tonewheels 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. Refer to Wheel Speed Sensor Clearance in the Specification Section in this section of the service manual. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 REMOVE 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4614 Speed Sensor Head Attachment To Steering Knuckle 5. Remove bolt attaching speed sensor to 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. INSTALL 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 shown ay result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4615 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 as shown. 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.). 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 pin. Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pin. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4616 Wheel Speed Sensor: Service and Repair Rear REMOVE 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4617 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 from the rear brake support plate. INSTALL 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. 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 (76 inch lbs.). 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. 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. 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. 9. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 hydraulic system for the base brakes must be bled anytime air enters the hydraulic system. Air can enter the hydraulic system for the base brakes due to the disconnection of brake lines, hoses or any other hydraulically operated component of the base brake system. The ABS system, particularly the Integrated Control Unit (ICU), should only be bled when the ICU is replaced or it is removed from the vehicle. The ICU must also always be bled if for any reason it is suspected that the ICU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic 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 the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ITT Teves Mark 20 ABS 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. This brake system can be either pressure bled or manually bled. The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires the use of the DRB Diagnostic Tester 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 pressurized bleeding equipment, refer to Bleeding Base Brakes. 1. Assemble and install all brake system components on the vehicle making sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the instrument panel to the left of the steering column cover. 3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault codes stored. If it does, remove them using the DRB. 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. 5. Using the DRB, 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 is free of any air 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 brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4622 Brake Bleeding: Service and Repair Base Brake System Bleeding CAUTION: Before removing the master cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. PRESSURE BLEEDING CAUTION: 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: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Air Trapped In Brake System 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. 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 Method For Purging Air From Brake System 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4623 Open Bleeder Screw At Least One Full Turn 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. BLEEDING WITHOUT A PRESSURE BLEEDER NOTE: Correct bleeding of the brakes hydraulic system without the use of pressure bleeding equipment will require the aid of a helper. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Pedal Ratio .......................................................................................................................................... ............................................................................ 3.32 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test Revisions NUMBER: 26-12-97I GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013 DESCRIPTION OF CHANGES Revisions to the ABS warning lamp test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4631 94 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4632 95 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4633 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4634 244 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 4635 245 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Page 4636 Brake Warning Indicator: Description and Operation Master Cylinder Fluid Level Sensor 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. 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 CAB. 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. If brake fluid level has dropped in master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Guide Pin Bolts 16 ft.lb Bleeder Screw 15 ft.lb Caliper To Knuckle Bolts 23 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4641 Exploded View Of Caliper Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4642 Brake Caliper: Service Precautions 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4643 Brake Caliper: Testing and Inspection CLEANING AND INSPECTION 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. 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 Service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. 2. Remove front wheel and tire assemblies from vehicle. Removing Caliper Guide Pin Bolts 3. Remove the 2 caliper to steering knuckle guide pin bolts. Removing/Installing Brake Caliper 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4646 Storing Caliper 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 135 Nm (100 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4647 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly 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. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4648 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 bunting 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4649 Assembly CAUTION: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4650 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171 or equivalents, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. 9. Install brake pads. 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. Guide Pin Bushing Service NOTE: The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this assembly can be serviced using the following procedure. REMOVING CALIPER GUIDE PIN BUSHINGS 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4651 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. 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. INSTALLING CALIPER GUIDE PIN BUSHINGS Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4652 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4653 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4654 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 lining may contain asbestos. This should be taken into account when servicing a vehicle's brake system, when after market 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 airtight 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Technician Safety Information > Page 4660 Brake Pad: Vehicle Damage Warnings 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 WARNING: Although factory installed brake linings are made from asbestos free materials, some after market brake lining may contain asbestos. This should be taken into account when servicing a vehicle's brake system, when after market 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 airtight 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. REMOVE 1. Raise vehicle on jackstands or centered on a hoist. Removing Caliper Guide Pin Bolts 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. Removing/Installing Brake Caliper Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4663 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. Storing Caliper 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. Removing/Installing Brake Rotor 7. Remove the brake rotor from the front hub. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4664 Removing/Installing Outboard Brake Shoe 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. 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 Caliper Disassembly And Re-Assembly Procedures in Disc Brake Caliper Service in this section of the service manual. 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 Guide Pin Bushing Service in Disc Brake Caliper Service in this section of the service manual. INSTALL 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). Front Brake Shoe 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4665 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. 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 Removing/Installing Brake Caliper 7. Carefully position brake caliper and brake shoes over brake rotor by first hooking top of brake shoes onto upper abutment on steering knuckle. 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 135 Nm (100 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 4666 Brake Pad: Service and Repair Cleaning and Inspection BRAKE PAD LINING WEAR If a visual inspection does not adequately determine the condition of the front disc brake shoe lining, a physical check will be necessary. To check the amount of brake shoe lining wear, remove the wheel and tire assemblies, and the calipers. Remove the front brake shoes. Combined front brake shoe 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 shoes (inboard and outboard) on both front sides of the vehicle. If the front disc brake shoes do not require replacement, reinstall, the brake shoes making sure each brake shoe is returned to the original position on the vehicle it was removed from. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Front Rear BRAKE ROTOR TYPE Ventilated Solid ROTOR THICKNESS 22.87 - 23.13 mm (0.900 - 0.911 in.) 8.87 - 9.13 mm (0.349 - 0.359 in.) MINIMUM ROTOR THICKNESS 21.4 mm (0.843 in.) 7.25 mm (0.285 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.) 0.013 mm (0.0005 in.) ROTOR RUNOUT * 0.13 mm (0.005 in.) 0.13 mm (0.005 in.) * TIR - Total Indicator Reading (measured on vehicle) ROTOR MICRO-FINISH 15 - 80 RMS 15 - 80 RMS Minimum Brake Rotor Thickness Markings Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4670 Brake Rotor/Disc: Testing and Inspection 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: 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. ROTOR RUNOUT AND THICKNESS VARIATION Checking Rotor For 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 run-outs 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 Adaptor, Special Tool SP-1910 or equivalents on steering arm. Dial indicator plunger should contact braking surface of rotor approximately 25 mm (1 inch) from edge of rotor. Check lateral runout (both sides of rotor) runout should not exceed 0.13 mm (0.005 inch). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4671 Marking Rotor And Wheel Stud 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. Checking Hub For Runout Install Dial Indicator, Special Tool C-3339 and Mounting Adaptor, 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4672 Index Rotor And Wheel Stud Runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, hub must be replaced. 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 un-machined surface of the rotor. Checking For For Thickness 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4673 Brake Rotor/Disc: Service and Repair NOTE: Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action. REFINISHING INFORMATION Refacing Brake Rotor Fig 7 Refacing Brake Disc -- Final Finish 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4674 Brake Rotor Refinishing Limits The illustrated chart shows the location of measurements and specifications when servicing the rotor. Minimum Brake Rotor Thickness Markings NOTE: All rotors have markings for minimum allowable thickness cast on an un-machined surface of 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 on 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 BRAKE ROTOR 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 BRAKE ROTOR 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 63 Nm (46 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4679 Backing Plate: Service and Repair REMOVE 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 4680 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. INSTALL 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 inch lbs.). 4. Install rear brake shoe assemblies on the brake support plate. 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 129 Nm (95 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Place the vehicle on a frame contact hoist with a helper in the driver's seat to apply the brakes. Raise the vehicle. Remove the adjuster access plug from the rear brake support plate automatic adjuster access hole. This will allow access to the adjuster quadrant on the automatic adjuster mechanism. Then, 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. Fully apply the brake pedal which will cause the brake shoes to leave the anchor. Upon application of the brake pedal, the adjuster quadrant should move. Thus, a definite rotation of the adjuster quadrant can 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation Brake Drum: Service and Repair Brake Drum Removal and Installation 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 brakes 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 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation > Page 4689 Brake Drum And Hub And Bearing Assembly 3. Remove rear brake drum from the rear hub and bearing assembly. 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 129 Nm (95 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation > Page 4690 Brake Drum: Service and Repair Brake Drum Refinishing 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 lining may contain asbestos. This should be taken into account when servicing a vehicle's brake system, when after market 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 airtight 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. 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. Drum Brake Assembly The original equipment rear drum brake assemblies used on this vehicle are supplied by Varga N.A. Inc. 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 off the brakes automatic self adjuster mechanism, using the following procedure. 3. Remove the rubber plug from the top of brake support plate. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4696 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. 5. Remove rear brake drum to hub/bearing retaining nuts (if equipped). Then remove rear brake drum from hub and bearing assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4697 6. Remove the actuating spring from the automatic adjuster mechanism and the trailing brake shoe. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4698 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4699 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4700 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. Installation Leading Brake Shoes Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4701 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. 1. Lubricate the eight brake shoe contact areas (indicated by arrows) on the support plate and anchor using Mopar Multi-Purpose Lubricant or equivalent. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4702 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4703 4. Install the automatic self adjuster mechanism on the correct leading brake shoe assembly using the reverse procedure as indicated in step Step 14 of the brake shoe removal procedure. Refer to image 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4704 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4705 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 torques to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4706 Brake Shoe: Service and Repair 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications To Support Plate Mounting Bolts 97 in.lb Bleeder Screw 75 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4710 Rear Wheel Cylinder (Exploded View) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 orate. 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 inch lbs.). 3. Hand start hydraulic brake hose tube, fitting to wheel cylinder. Tighten the tube nut to a torque of 17 Nm (145 inch lbs.). 4. Install brake shoes on support plate. 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 129 Nm (95 ft. lbs.). 7. Bleed the entire brake system. 8. Adjust the rear brakes. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4713 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4714 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. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 hydraulic system for the base brakes must be bled anytime air enters the hydraulic system. Air can enter the hydraulic system for the base brakes due to the disconnection of brake lines, hoses or any other hydraulically operated component of the base brake system. The ABS system, particularly the Integrated Control Unit (ICU), should only be bled when the ICU is replaced or it is removed from the vehicle. The ICU must also always be bled if for any reason it is suspected that the ICU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic 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 the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ITT Teves Mark 20 ABS 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. This brake system can be either pressure bled or manually bled. The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires the use of the DRB Diagnostic Tester 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 pressurized bleeding equipment, refer to Bleeding Base Brakes. 1. Assemble and install all brake system components on the vehicle making sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the instrument panel to the left of the steering column cover. 3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault codes stored. If it does, remove them using the DRB. 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. 5. Using the DRB, 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 is free of any air 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 brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4720 Brake Bleeding: Service and Repair Base Brake System Bleeding CAUTION: Before removing the master cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder. PRESSURE BLEEDING CAUTION: 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: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. Air Trapped In Brake System 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. 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 Method For Purging Air From Brake System 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 4721 Open Bleeder Screw At Least One Full Turn 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. BLEEDING WITHOUT A PRESSURE BLEEDER NOTE: Correct bleeding of the brakes hydraulic system without the use of pressure bleeding equipment will require the aid of a helper. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Guide Pin Bolts 16 ft.lb Bleeder Screw 15 ft.lb Caliper To Knuckle Bolts 23 ft.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4725 Exploded View Of Caliper Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4726 Brake Caliper: Service Precautions 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4727 Brake Caliper: Testing and Inspection CLEANING AND INSPECTION 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. 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 Service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. 2. Remove front wheel and tire assemblies from vehicle. Removing Caliper Guide Pin Bolts 3. Remove the 2 caliper to steering knuckle guide pin bolts. Removing/Installing Brake Caliper 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4730 Storing Caliper 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 135 Nm (100 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4731 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly 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. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4732 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 bunting 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4733 Assembly CAUTION: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4734 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171 or equivalents, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. 9. Install brake pads. 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. Guide Pin Bushing Service NOTE: The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this assembly can be serviced using the following procedure. REMOVING CALIPER GUIDE PIN BUSHINGS 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4735 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. 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. INSTALLING CALIPER GUIDE PIN BUSHINGS Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4736 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4737 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4738 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4742 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact-rinse eyes thoroughly with water. * Skin Contact-wash skin with soap and water. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4743 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 4744 Brake Fluid: Service and Repair BRAKE FLUID LEVEL CHECK Check master cylinder reservoir brake fluid level a minimum of twice a year. Master Cylinder Fluid Level Master cylinder reservoirs are marked with the words FULL AND MIN indicating proper range of the 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Description and Operation Brake Fluid Accumulator: Description and Operation There are two fluid accumulators in all hydraulic control units, one each for the primary and secondary hydraulic circuits. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This fluid is then used by the pump in the valve body to provide build pressure for the brake hydraulic system. Additionally on vehicles that are equipped with only ABS (non-traction control vehicles) there is a mini accumulator on the secondary hydraulic circuit which protects the master cylinder's seals during an ABS stop. There is also a noise damping chamber on the primary hydraulic circuit. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp circuit. This switch does not disable the ABS system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 4751 Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the 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 the retaining tabs on the end of the brake fluid level sensor. Removing Fluid Level Switch From Reservoir Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 4752 3. While compressing retaining tabs, grasp opposite end of brake fluid level sensor and pull it out of master cylinder fluid reservoir. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 843 > Nov > 99 > Recall - Right Rear Brake Tube Brake Hose/Line: Recalls Recall - Right Rear Brake Tube NO 843 DATE November 1999 Safety Recall No. 843- Right Rear Brake Tube Models 1998-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze NOTE: This recall applies only to the above vehicles built through May 12 1999 (MDH O512O7) IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requiremen~to apply to used vehicle inventory and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject: The right rear brake tube on about 365,000 of the above vehicles may contact an exhaust system clamp. Prolonged brake tube contact may cause the tube to rub through and leak, resulting in a partial brake system loss and increased stopping distance; The increased stopping distance can cause an accident without warning. Repair The right rear brake tube must be inspected for evidence of contact and/or wear and repositioned. Brake tubes that have been in contact with the exhaust clamp must be replaced. Alternate Transportation If inspection determines that brake tube replacement is required and the vehicle must be held 6vemight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive two (2) non-ABS brake tubes, PN 05017469AA, and one (1) ABS brake tube, PN 05017466AA. Additional brake tubes should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require brake tube replacement The appropriate brake tube for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or > Entering the VIN to the DIAL VIP system (sales code information) along with the following table (all dealers). Parts Information Parts Information Service Procedure A. Inspect Right Rear Brake Tube Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 843 > Nov > 99 > Recall - Right Rear Brake Tube > Page 4761 1. Raise the vehicle on an appropriate hoist. Figure 1 2. Inspect the right rear brake tube for evidence of contact with the exhaust system clamp located just forward of the rear axle kick up (Figure 1) > If the brake tube surface is damaged from contact with the exhaust clamp, the brake tube must be replaced. Continue with Section "B" - Replace Right Rear Brake Tube. > If the brake tube is NOT damaged, reposition the tube by snapping it into the existing tube clip (Figure 1), then lower the vehicle and return it to the customer. No further action is necessary. B. Replace Right Rear Brake Tube: NOTE: Only those vehicles that have damaged brake tubes, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake tube replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the right rear brake will require bleeding. 3. Raise the vehicle on the hoist. 4. Disconnect the right rear brake tube from the rear brake hose (non-ABS) or from the rear proportioning valve (ABS). NOTE: Do not allow brake fluid to drip or spill on painted surfaces as this may damage the paint. 5. Disconnect the two (2) right rear parking brake cable clips. 6. On vehicles equipped with ABS, remove the right front splash shield. 7. On vehicles equipped with ABS, remove the Hydraulic Control Unit (RCU) heat shield. 8. Disconnect the right rear brake tube from the front proportioning valve (non-ABS) or from the HCU (ABS). 9. Remove the right rear brake tube from the underbody clips and then remove and discard the tube. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 843 > Nov > 99 > Recall - Right Rear Brake Tube > Page 4762 NOTE: On vehicles equipped with ABS, route the tube forward through the right front wheel well opening to remove. 10. Install the new brake tube into ALL of the underbody clips. 11. Connect the front of the brake tube to the proportioning valve (non-ABS) or HCU (ABS). Torque the brake tube fitting to 145 in-lbs (16 N.m). 12. On vehicles equipped with ABS, install the HCU heat shield. 13. On vehicles equipped with ABS, install the right front splash shield. 14. Connect the brake tube to the right rear brake hose (non-ABS) or rear proportioning valve (ABS). Torque the brake tube fitting to 145 in-lbs (16N.m). 15. Install the two (2) right rear parking brake cable clips. 16. Bleed the right rear brake circuit as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). 17. Inspect brake tube connections to insure that there are no leaks and then test drive the vehicle to verify that the brakes are operating properly and the pedal feel is correct. 18. Lower the vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Times Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Add the cost of the brake tube, if necessary, 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 843 > Nov > 99 > Recall - Right Rear Brake Tube > Page 4763 Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD843". 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 notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicles Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > NHTSA99V244000 > Sep > 99 > Recall 99V244000: Rear Brake Tube Leakage Brake Hose/Line: Recalls Recall 99V244000: Rear Brake Tube Leakage The right rear brake tube can contact the exhaust system clamp and wear a hole in it. If this happens, the tube could leak, reducing the effectiveness of one-half of the diagonally split braking system, and resulting in longer stopping distances. Dealers will inspect the brake tubes for visible evidence of contact with the exhaust system clamp. If the tube shows evidence of contact, it will be replaced. If no evidence of contact exists, the tube will be fastened with a clip. Owner notification began November 22, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 843 > Nov > 99 > Recall Right Rear Brake Tube Brake Hose/Line: All Technical Service Bulletins Recall - Right Rear Brake Tube NO 843 DATE November 1999 Safety Recall No. 843- Right Rear Brake Tube Models 1998-1999 (JA) Chrysler Cirrus, Dodge Stratus and Plymouth Breeze NOTE: This recall applies only to the above vehicles built through May 12 1999 (MDH O512O7) IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requiremen~to apply to used vehicle inventory and should perform this recall on vehicles in for service as determined by using the DIAL VIP System. Subject: The right rear brake tube on about 365,000 of the above vehicles may contact an exhaust system clamp. Prolonged brake tube contact may cause the tube to rub through and leak, resulting in a partial brake system loss and increased stopping distance; The increased stopping distance can cause an accident without warning. Repair The right rear brake tube must be inspected for evidence of contact and/or wear and repositioned. Brake tubes that have been in contact with the exhaust clamp must be replaced. Alternate Transportation If inspection determines that brake tube replacement is required and the vehicle must be held 6vemight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive two (2) non-ABS brake tubes, PN 05017469AA, and one (1) ABS brake tube, PN 05017466AA. Additional brake tubes should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require brake tube replacement The appropriate brake tube for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the following table (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or > Entering the VIN to the DIAL VIP system (sales code information) along with the following table (all dealers). Parts Information Parts Information Service Procedure A. Inspect Right Rear Brake Tube Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 843 > Nov > 99 > Recall Right Rear Brake Tube > Page 4773 1. Raise the vehicle on an appropriate hoist. Figure 1 2. Inspect the right rear brake tube for evidence of contact with the exhaust system clamp located just forward of the rear axle kick up (Figure 1) > If the brake tube surface is damaged from contact with the exhaust clamp, the brake tube must be replaced. Continue with Section "B" - Replace Right Rear Brake Tube. > If the brake tube is NOT damaged, reposition the tube by snapping it into the existing tube clip (Figure 1), then lower the vehicle and return it to the customer. No further action is necessary. B. Replace Right Rear Brake Tube: NOTE: Only those vehicles that have damaged brake tubes, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake tube replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the right rear brake will require bleeding. 3. Raise the vehicle on the hoist. 4. Disconnect the right rear brake tube from the rear brake hose (non-ABS) or from the rear proportioning valve (ABS). NOTE: Do not allow brake fluid to drip or spill on painted surfaces as this may damage the paint. 5. Disconnect the two (2) right rear parking brake cable clips. 6. On vehicles equipped with ABS, remove the right front splash shield. 7. On vehicles equipped with ABS, remove the Hydraulic Control Unit (RCU) heat shield. 8. Disconnect the right rear brake tube from the front proportioning valve (non-ABS) or from the HCU (ABS). 9. Remove the right rear brake tube from the underbody clips and then remove and discard the tube. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 843 > Nov > 99 > Recall Right Rear Brake Tube > Page 4774 NOTE: On vehicles equipped with ABS, route the tube forward through the right front wheel well opening to remove. 10. Install the new brake tube into ALL of the underbody clips. 11. Connect the front of the brake tube to the proportioning valve (non-ABS) or HCU (ABS). Torque the brake tube fitting to 145 in-lbs (16 N.m). 12. On vehicles equipped with ABS, install the HCU heat shield. 13. On vehicles equipped with ABS, install the right front splash shield. 14. Connect the brake tube to the right rear brake hose (non-ABS) or rear proportioning valve (ABS). Torque the brake tube fitting to 145 in-lbs (16N.m). 15. Install the two (2) right rear parking brake cable clips. 16. Bleed the right rear brake circuit as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). 17. Inspect brake tube connections to insure that there are no leaks and then test drive the vehicle to verify that the brakes are operating properly and the pedal feel is correct. 18. Lower the vehicle. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Times Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Add the cost of the brake tube, if necessary, 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 843 > Nov > 99 > Recall Right Rear Brake Tube > Page 4775 Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD843". 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 notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicles Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > NHTSA99V244000 > Sep > 99 > Recall 99V244000: Rear Brake Tube Leakage Brake Hose/Line: All Technical Service Bulletins Recall 99V244000: Rear Brake Tube Leakage The right rear brake tube can contact the exhaust system clamp and wear a hole in it. If this happens, the tube could leak, reducing the effectiveness of one-half of the diagonally split braking system, and resulting in longer stopping distances. Dealers will inspect the brake tubes for visible evidence of contact with the exhaust system clamp. If the tube shows evidence of contact, it will be replaced. If no evidence of contact exists, the tube will be fastened with a clip. Owner notification began November 22, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 4780 Brake Hose/Line: Specifications Intermediate Bracket Bolt .................................................................................................................... ..................................................... 23 Nm (17 ft. lbs.) To Caliper Banjo Bolt ....................................... ....................................................................................................................................... 48 Nm (35 ft. lbs.) Tube Nuts To Fittings And Components ............................................................................................................................................. 17 Nm (145 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 4781 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Brake Hoses > Page 4784 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring Brake Hose/Line: Service and Repair Brake Tubing Repair/Tube Flaring BRAKE TUBE REPAIR Only double wall 4.75 mm (3/16 inch) 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. Cutting And Flaring Of Brake Fluid Tubing Tube End Properly Prepared For Flaring 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. PLACE TUBE NUT ON TUBING BEFORE FLARING THE TUBING. DOUBLE INVERTED TUBING FLARES Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4787 Double Inverted Brake Tube Flare 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4788 Brake Hose/Line: Service and Repair Brake Tubing/Hose Replacement 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. 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 4.75mm (3/16 inch) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Mechanical Specifications Brake Proportioning/Combination Valve: Mechanical Specifications With Antilock Brakes Material ................................................................................................................................................ ................................................................. Aluminum Function ............................................................ ................................................................................................................ Hydraulic Pressure Proportioning Without Antilock Brakes Material ................................................................................................................................................ ................................................................. Aluminum Function ............................................................ ................................................................................................................ Hydraulic Pressure Proportioning Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Mechanical Specifications > Page 4793 Brake Proportioning/Combination Valve: Pressure, Vacuum and Temperature Specifications With Antilock Brakes Split Point ............................................................................................................................................ ....................................................................... 500 psi Slope ............................................................... .............................................................................................................................................................. .. 0.43 Inlet Pressure ........................................................................................................................... ................................................................................. 1000 psi Outlet Pressure ................................... .............................................................................................................................................................. . 600 - 700 psi Without Antilock Brakes Split Point ............................................................................................................................................ ....................................................................... 500 psi Slope ............................................................... .............................................................................................................................................................. .. 0.43 Inlet Pressure ........................................................................................................................... ................................................................................. 1000 psi Outlet Pressure ................................... .............................................................................................................................................................. . 600 - 700 psi Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4794 Brake Proportioning/Combination Valve: Description and Operation Proportioning Valves For Non Abs Equipped Vehicles This vehicle uses two screw-in proportioning valves inline with the rear brake tubes. The in-line proportioning valves used in the Teves Mark 20 ABS system replace the combination valve used in prior designs. With this new design, the chassis brake tubes connect directly from the master cylinder or Hydraulic Control Unit (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 proportioning valves in-line with each of the rear wheel chassis brake tubes. The non-ABS equipped proportioning valves are located on the front suspension crossmember in the same area as the hydraulic unit on ABS equipped vehicles. Proportioning Valve Location For Antilock Brake Equipped Vehicles On vehicles equipped with antilock brakes, the proportioning valve is located at the rear of the vehicle. The proportioning valve mounts directly to the flex hose for the rear wheel brakes and has the chassis brake tube for each rear brake connected directly to it. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4795 Proportioning Valve With ABS And Non-ABS TLEV 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 stone is 0.43. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > General Testing Brake Proportioning/Combination Valve: Testing and Inspection General Testing CAUTION: Proportioning valves should never be disassembled. Proportioning Valve 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 skids first is essential. If a malfunctioning proportioning valve is suspected on a vehicle equipped with ABS brakes, refer to Testing Procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > General Testing > Page 4798 Brake Proportioning/Combination Valve: Testing and Inspection Proportioning Valve Testing With Antilock Brakes 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. Proportioning Valve Location 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. The test procedure is the same for both rear wheel proportioning valves. After road testing vehicle to determine which wheel skids first, follow the procedure below for testing the required proportioning valve. 1. Remove the chassis brake tube from the proportioning valve controlling the rear wheel of the vehicle which has premature wheel skid. Proportioning Valve Removal CAUTION: When removing proportioning valve from flex hose place wrench on proportioning valve not adapter fitting. The adapter fitting is not to be removed from the proportioning valve. 2. Remove proportioning valve from brake flex hose. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > General Testing > Page 4799 Brake Hose Mounting Bracket 3. Remove the brake flex hose mounting bracket from the frame rail. CAUTION: Be sure the pressure test fittings being installed into the proportioning valve have the correct thread sizes and flares for installation into the proportioning valve and for installation of the chassis brake tubes. Pressure Test Fittings Installed On Proportioning Valve 4. Install Pressure Test Fitting, Special Tool 6833-1 or equivalent in the inlet port of the proportioning valve. Install Pressure Test Fitting, Special Tool 8187-2 or equivalent in the outlet port of the proportioning valve. Tighten tube nuts to a torque of 17 Nm (145 inch lbs.). Proportioning Valve With Pressure Test Fittings Installed 5. Install proportioning valve Pressure Test Fitting, Special Tool 8187-2 or equivalent on brake flex hose and securely tighten. Install the chassis brake tube in Pressure Test Fitting, Special Tool 6833-1 or equivalent. Tighten tube nut to a torque of 17 Nm (145 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > General Testing > Page 4800 Pressure Gauges Installed On Pressure Test Fittings 6. 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. Proportioning Valve Applications And Pressure Specifications 7. With the aid of a helper, apply pressure to the brake pedal until reading on proportioning valve inlet gauge, is at the pressure shown. Then check the pressure reading on the proportioning valve outlet gauge. If proportioning valve outlet pressure does not agree with value shown, when inlet pressure shown on chart is obtained, replace the proportioning valve. If proportioning valve is within pressure specifications do not replace proportioning valve. 8. 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. 9. Install proportioning valve on end of brake flex hose. Tighten the proportioning valve to a torque of 17 Nm (145 inch lbs.). 10. Install brake tube on proportioning valve. Torque tube nut to 17 Nm (145 inch lbs.) torque. 11. Bleed the affected brake line. Without Antilock Brakes 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > General Testing > Page 4801 Non-ABS Brake Proportioning Valve Location 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, use the following procedure to diagnose the proportioning valve. The test procedure for a premature rear wheel skid is the same for both rear wheel proportioning valves. 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. 1. After road testing vehicle to determine which rear wheel exhibits premature rear wheel skid, refer to image 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. Remove the proportioning valve from the rear brake chassis tube. CAUTION: Be sure the pressure test fittings being installed into proportioning valve, have the correct thread sizes for installation into the proportioning valve and installation of rear brake line tube nut. Pressure Test Fitting Installed In Proportioning Valve 4. Install Pressure Test Fitting, Special Tool 8187 or equivalent in the inlet port of the proportioning valve. Install Pressure Test Fitting, Special Tool 8187-2 or equivalent in the outlet port of the proportioning valve. Tighten tube nuts to a torque of 17 Nm (145 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > General Testing > Page 4802 Proportioning Valve With Pressure Test Fittings Installed 5. Install the proportioning valve with the pressure test fittings installed, in the chassis brake tube. Tighten both tube nuts to a torque of 17 Nm (145 inch lbs.). Pressure Gauges Installed On Pressure Test Fittings 6. 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. hose. Proportioning Valve Applications And Pressure Specifications 7. 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 chart in the image. Then check the pressure reading on the proportioning valve outlet gauge. If proportioning valve outlet pressure does not agree with value shown on the chart in the image, when inlet pressure shown on chart is obtained, replace the proportioning valve. If proportioning valve is within pressure specifications do not replace proportioning valve. 8. 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. 9. Install proportioning valve in rear brake line and hand tighten both tube nuts until they are fully seated in proportioning valve. 10. Tighten both brake line tube nuts at the proportioning valve to a torque of 17 Nm (145 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > General Testing > Page 4803 11. Bleed the affected brake line. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 CAUTION: Proportioning valves should never be disassembled. REMOVE Proportioning Valve Location 1. Remove chassis brake from proportioning valve controlling the rear wheel of the vehicle which has premature wheel skid. CAUTION: When removing proportioning valve from flex hose place wrench on proportioning valve not adapter fitting. The adapter fitting is not to be removed from the proportioning valve. Proportioning Valve Removal 2. Remove proportioning valve from brake flex hose. INSTALL 1. Install proportioning valve on brake flex hose. Tighten proportioning valve to a torque of 17 Nm (145 inch lbs.). 2. Install brake tube on proportioning valve. Tighten tube nuts to 17 Nm (145 inch lbs.) torque. 3. Bleed the affected brake line. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4806 Brake Proportioning/Combination Valve: Service and Repair Without Antilock Brakes REMOVE Non-ABS Brake Proportioning Valve Location 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 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 inch lbs.). 3. Bleed the affected brake line. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Page 4807 Brake Proportioning/Combination Valve: Tools and Equipment The 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 test to verify proportioning valve is maintaining the required hydraulic pressure to the rear wheel brake which it controls. 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. Proportioning Valve Pressure Test Gauge Set The pressure gauges used for testing the in-line proportioning valves on both non-ABS and ABS brakes, is Pressure Gauge Set, Special Tool C-4007-A, or equivalent currently used for testing the combination valve. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications To Mounting Bracket Bolts .................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Bracket To Crossmember Mounting Bolts .......................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information Teves Mark 20 ICU The hydraulic control unit (HCU) used with the Teves Mark 20 ABS is different from the HCU used on previous Chrysler products with ABS. The HCU used on this ABS system is part of the Integrated Control Unit (ICU). The HCU is part of what is referred to as the ICU because the HCU and the Controller Antilock Brakes (CAB) are combined (integrated) into one unit. This differs from previous Chrysler products with ABS, where the HCU and the CAB were separate components located in different areas of the vehicle. NOTE: The HCU and CAB used on a vehicle that is equipped with only ABS and on a vehicle that is equipped with ABS and traction control are different. The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is approximately 1 inch longer on the low pressure fluid accumulators side than a HCU for a vehicle that is equipped with only ABS. ICU Mounting Location The ICU is located on the passenger side of the vehicle, and is mounted to the front suspension crossmember. The ABS only ICU contains the following components for controlling the brake system hydraulic pressure during ABS braking: The CAB, eight valve solenoids, (four inlet valves and four outlet valves) fluid accumulators a pump, and an electric motor. CAUTION: No components of the ICU are serviceable. If any component that makes up the ICU is diagnosed as not functioning properly it MUST be replaced. The replaceable components of the ICU, are the HCU and the CAB. The mounting bracket is also replaceable as a separate component of the ICU. The remaining components of the ICU are not serviceable items. No attempt should ever be made to remove or service any individual components of the HCU. This is due to the concern of contamination entering the HCU while performing a service procedure. Also no attempt should ever be made to remove or service any individual components of the CAB. CAUTION: At no time when servicing the ICU should a 12 volt power source be applied to any electrical connector of the HCU or the CAB. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information > Page 4813 Hydraulic Control Assembly - Antilock Brakes: Description and Operation System Operation ICU Mounting Location General Information The Hydraulic Control Unit (HCU) contains the valve block assembly, two accumulators, and pump/motor assembly. The HCU is mounted on the crossmember over the steering gear on the right side. Valve Block Assembly The valve block assembly contains valves with four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position. During and antilock stop, these valves are cycled to maintain the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and further pressure increase. Then the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant. On JX and NS Bodies which are equipped with a traction control system, there are two additional valves that isolate the master cylinder and rear wheels. During a traction control situation the brakes are applied to reduce wheel slippage. Pump/Motor Assembly The pump/motor assembly provides the extra amount of fluid needed during antilock braking. The pump is supplied fluid that is released to the accumulators when the outlet valve is opened during and antilock stop. The pump is also used to drain the accumulator circuits after the antilock stop is complete. The pump is operated by an integral electric motor. This DC-type motor is controlled by the Control Antilock Brake (CAB). The CAB may turn on the pump motor when an antilock stop is detected. The pump continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor will run to drain the accumulators during the next drive off. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft secondary hydraulic circuit. In operation, one piston craw fluid from the accumulators. The opposing piston pumps fluid to the valve body solenoids. The CAB monitors the pump/motor operation internally. Accumulators The accumulators provide temporary fluid storage during an antilock stop and are drained by the pump/motor. Each of the diagonal circuits uses a 3cc. accumulator. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information > Page 4814 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Valves and Solenoids INLET VALVES AND SOLENOIDS There are four inlet solenoid valves, one for each wheel. In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle. When the ABS cycle has been completed the inlet solenoids will return to their released (open) position. OUTLET VALVES AND SOLENOIDS There are four outlet solenoid valves, one for each wheel. In the released position they are closed to allow for normal braking. In the actuated (open) position, they provide a fluid path from the wheel brakes of the vehicle to the ICU fluid accumulators and pump motor. The outlet valves are spring loaded in the released (closed) position during normal braking. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal Ground Cable Attachment At Strut Tower 1. Remove the remote ground cable from the ground stud 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 and installing the nut on the stud. This will prevent accidental grounding of the remote ground cable. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4817 4. Raise vehicle on jackstands or centered on a hoist. Right Side Splash Shield 5. Remove the splash shield from the right side of the engine compartment. 6. Remove entire exhaust system from the vehicle as a complete assembly using the following steps. a. Disconnect the oxygen sensor wiring harnesses from the vehicle wiring harness. b. Remove the ground strap between the frame and muffler at the muffler bracket. Exhaust Pipe Mounting To Exhaust Manifold c. Remove attaching bolts from exhaust pipe at exhaust manifold on engine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4818 Exhaust System Support/Isolators Locations d. 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. e. Lower exhaust system as a complete assembly away from the underbody of the vehicle. HCU Heat Shield 7. Remove the heat shield for the Hydraulic Control Unit (HCU) from the HCU mounting bracket. 8. Using Mopar, Brake Parts Cleaner or an equivalent, thoroughly clean all surfaces of the HCU. Also, thoroughly clean all brake tube to HCU connections. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4819 Chassis Brake Tube Connections To HCU 9. Remove the 4 chassis brake tubes from the outlet ports on the HCU. Master Cylinder Brake Tube Connections To HCU 10. Remove the primary and secondary brake tubes coming from the master cylinder from the HCU inlet ports. HCU Mounting Bracket Front Bolt 11. Remove the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember. HCU Mounting Bracket Rear Bolts Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4820 12. Remove the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember. HCU To Bracket Mounting Bolt 13. Remove bolt attaching the side of the HCU to the mounting bracket. HCU To Bracket Mounting Bolt 14. Remove the 2 bolts attaching the top of the HCU to the mounting bracket. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 HCU connector when disconnected from the Controller Antilock Brakes (CAB). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4821 Unlocked CAB Connector 15. Disconnect the 25 way wiring harness connector from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it out from the connector as far as possible. This will unlock and raise the 25 way connector out of the socket on the CAB. HCU Remove And Install 16. Remove the HCU from its mounting bracket. Then remove the HCU from the vehicle by pulling it out through the area between the right drive shaft and frame rail. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4822 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Installation 1. Install the Hydraulic Control Unit (HCU) back in the vehicle and on its mounting bracket using the reverse order of its removal. HCU To Bracket Mounting Bolt HCU To Bracket Mounting Bolt 2. Install isolators, washers and attaching bolts, mounting the HCU to its mounting bracket. 3. Tighten the 3 HCU mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: Before installing the 25 way connector in the Controller Antilock Brakes (CAB) be sure that the seal is properly installed in the connector. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4823 Unlocked CAB Connector 4. Install the 25 way connector into the socket on the CAB. The connector is installed using the following procedure. Position the 25 way connector in the socket on the CAB and carefully push it down as far as it will go. When connector is fully seated into the CAB socket push in the connector lock as far as it will go. This will pull the 25 connector into the socket on the CAB and lock it in the installed position. HCU Mounting Bracket Rear Bolts 5. Install the 2 bolts attaching the back legs of the HCU mounting bracket to the front suspension crossmember. HCU Mounting Bracket Front Bolt Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4824 6. Install the bolt attaching the front leg of the HCU mounting bracket to the front suspension crossmember. 7. Tighten the 3 bolts mounting the HCU mounting to the front suspension crossmember to a torque of 28 Nm (250 inch lbs.). Master Cylinder Brake Tube Connections To HCU 8. Install the primary and secondary brake tubes coming from the master cylinder in the HCU inlet ports. Chassis Brake Tube Connections To HCU 9. Install the 4 chassis brake tubes in the outlet ports on the HCU. Torquing Primary And Secondary Brake Tube Nut Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4825 Torquing Chassis Brake Tube Nuts 10. Using a crow foot tighten all of the brake tube nuts to a torque of 17 Nm (146 inch lbs.). HCU Heat Shield 11. Install the HCU heat shield on the HCU mounting bracket. Install and securely tighten the attaching bolt. 12. Install exhaust system in vehicle using the reverse steps of its removal. Right Side Splash Shield 13. Install right side engine compartment splash shield back on the vehicle. 14. Lower vehicle. 15. Remove brake pedal holding tool. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 4826 Ground Cable Attachment At Strut Tower 16. 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.). 17. Bleed the base brakes and the ABS brakes hydraulic system. 18. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes Brake Master Cylinder: Specifications With Antilock Brakes GENERAL SPECIFICATIONS: Bore/Stroke ................................................................................................................................................. 22.2 mm x 33.4 mm (0.874 inch x 1.32 inch) Displacement Split ................................................................ .................................................................................................................................... 50/50 Primary Outlet Ports .......................................................................................................................................... ...................................................... 3/8-24 Secondary Outlet Ports ..................................................... ..................................................................................................................................... 7/16-24 Outlet Fitting Type .......................................................................................................................................... ....................... Double Wall Inverted Flare TIGHTENING SPECIFICATIONS: To Vacuum Booster Mounting Nut ................................................................................................................................................. 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes > Page 4831 Brake Master Cylinder: Specifications Without Antilock Brakes GENERAL SPECIFICATIONS: Bore/Stroke ................................................................................................................................................. 22.2 mm x 33.4 mm (0.874 inch x 1.32 inch) Displacement Split ................................................................ .................................................................................................................................... 50/50 Primary Inboard And Outboard Outlet Ports ......................................................................................................................................................... 7/16-24 Secondary Inboard And Outboard Outlet Ports ....................................................................................................................................................... 3/8-23 Outlet Fitting Type .................................................................................................................... ............................................. Double Wall Inverted Flare TIGHTENING SPECIFICATIONS: To Vacuum Booster Mounting Nut ................................................................................................................................................. 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes Brake Master Cylinder: Description and Operation With Antilock Brakes This vehicle uses 2 differently designed master cylinder assemblies depending on whether the vehicle is or is not equipped with antilock brakes. Vehicles not equipped with ABS use a standard compensating port master cylinder design, while vehicles equipped with ABS use a center valve design master cylinder. Vehicles equipped with rear drum brakes use a master cylinder with a 22 mm diameter piston bore. Vehicles equipped with rear disc brakes use a master cylinder with a 7/8 inch diameter piston bore. On vehicles equipped with ABS brakes, the master cylinder is a two outlet design. On vehicles not equipped with ABS brakes, the master cylinder is a 4 outlet design. All vehicles are equipped with a master cylinder having a bore diameter of 22.2 mm. Master Cylinder The 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. Primary And Secondary Ports Without ABS On Non-ABS master cylinders, 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 4834 Master Cylinder Primary And Secondary Ports With ABS On ABS master cylinders, the primary outlet port supplies hydraulic pressure to the right front and left rear brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes. Master Cylinder And Vacuum Booster A vehicle equipped with the Teves Mark 20 ABS (without traction control) uses a different master cylinder and power brake booster then a vehicle that is not equipped with antilock brakes. A vehicle equipped with ABS uses a center port master cylinder while a vehicle which is not equipped with ABS uses a compensating port master cylinder. The primary and secondary outlet ports on the master cylinder go directly to the Hydraulic Control Unit (HCU). A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp circuit. This switch does not disable the ABS system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 4835 Brake Master Cylinder: Description and Operation Without Antilock Brakes This vehicle uses 2 differently designed master cylinder assemblies depending on whether the vehicle is or is not equipped with antilock brakes. Vehicles not equipped with ABS use a standard compensating port master cylinder design, while vehicles equipped with ABS use a center valve design master cylinder. Vehicles equipped with rear drum brakes use a master cylinder with a 22 mm diameter piston bore. Vehicles equipped with rear disc brakes use a master cylinder with a 7/8 inch diameter piston bore. On vehicles equipped with ABS brakes, the master cylinder is a two outlet design. On vehicles not equipped with ABS brakes, the master cylinder is a 4 outlet design. All vehicles are equipped with a master cylinder having a bore diameter of 22.2 mm. Master Cylinder The 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. Primary And Secondary Ports Without ABS On Non-ABS master cylinders, 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 4836 Master Cylinder Primary And Secondary Ports With ABS On ABS master cylinders, the primary outlet port supplies hydraulic pressure to the right front and left rear brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Without ABS Bleeding Tubes Attached To Master Cylinder Without ABS 1. Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802 or equivalent to the master cylinder outlet ports. Position bleeding 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. Bleeding Master Cylinder 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. NOTE: It is not necessary to bleed the brakes entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been thoroughly bled and filled to the proper level upon installation on the power brake vacuum booster. With ABS Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4839 1. Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802 or equivalent to the master cylinder outlet ports. Position bleeding 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. Bleeding Master Cylinder 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. NOTE: It is not necessary to bleed the brakes entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been thoroughly bled and filled to the proper level upon installation on the power brake vacuum booster. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4840 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Without ABS REMOVE Master Cylinder Fluid Level Sensor 1. Remove vehicle wiring harness connector from brake fluid level sensor, in master cylinder brake fluid reservoir. Primary And Secondary Ports Without ABS 2. Disconnect the primary and secondary brake tubes from 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 area where master cylinder attaches to booster. Master Cylinder Mounting To Vacuum Booster Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4841 4. Remove the 2 nuts attaching master cylinder assembly to power brake vacuum booster. 5. Slide master cylinder assembly straight off its mounting studs on power brake vacuum booster. BLEEDING MASTER CYLINDER Bleeding Tubes Attached To Master Cylinder Without ABS 1. Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802 or equivalent to the master cylinder outlet ports. Position tubes so outlets of Bleeding Tubes will be below surface of 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. Bleeding Master Cylinder 3. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to 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 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. NOTE: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been bled and filled upon installation. 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. 2. Install the 2 master cylinder to power brake vacuum booster mounting nuts. Tighten both nuts to a torque of 28 Nm (250 inch lbs.). 3. Connect brake tubes to master cylinder primary and secondary ports. Then tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). With ABS REMOVE Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4842 Master Cylinder Fluid Level Sensor 1. Remove vehicle wiring harness connector from brake fluid level sensor, in master cylinder brake fluid reservoir. Master Cylinder Primary And Secondary Ports With ABS 2. Disconnect the primary and secondary brake tubes from 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 area where master cylinder attaches to booster. Master Cylinder Mounting To Vacuum Booster 4. Remove the 2 nuts attaching master cylinder assembly to power brake vacuum booster. 5. Slide master cylinder assembly straight off its mounting studs on power brake vacuum booster. BLEEDING MASTER CYLINDER Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4843 1. Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802 or equivalent to the master cylinder outlet ports. Position tubes so outlets of Bleeding Tubes will be below surface of 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. Bleeding Master Cylinder 3. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to 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 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. NOTE: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder. However, the master cylinder must have been bled and filled upon installation. 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. 2. Install the 2 master cylinder to power brake vacuum booster mounting nuts. Tighten both nuts to a torque of 28 Nm (250 inch lbs.). 3. Connect brake tubes to master cylinder primary and secondary ports. Then tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4844 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement 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. Removing Fluid Reservoir From Master Cylinder 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications To Support Plate Mounting Bolts 97 in.lb Bleeder Screw 75 in.lb Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4848 Rear Wheel Cylinder (Exploded View) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 orate. 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 inch lbs.). 3. Hand start hydraulic brake hose tube, fitting to wheel cylinder. Tighten the tube nut to a torque of 17 Nm (145 inch lbs.). 4. Install brake shoes on support plate. 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 129 Nm (95 ft. lbs.). 7. Bleed the entire brake system. 8. Adjust the rear brakes. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4851 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4852 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. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. 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. 3. If the vehicle is equipped with a manual transmission remove the gearshift knob and shifter boot using the following procedure. Gearshift Knob - Push shifter boot down to expose clips on gearshift 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4858 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. Center Console Front Attaching Screws (Automatic) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4859 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4860 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 inch wrench over the park brake cable retainer as indicated. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4861 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4862 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 inch 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4863 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4864 Parking Brake Cable: Service and Repair Cable Installation 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) 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4865 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4866 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 cries cross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 129 Nm (95 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4867 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4868 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. 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. Park Brake Lever Output Cable Adjustment - Tighten adjusting nut on park brake lever output cable until 12 mm millimeters 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4869 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4870 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4871 Parking Brake Cable: Service and Repair Lever Output Cable Park Brake Lever Mechanism 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Lever Mounting Nuts ........................................................................................................................... ............................................... 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4875 Parking Brake Lever: Service and Repair REMOVE 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. 3. If the vehicle is equipped with a manual transmission remove the gearshift knob and shifter boot using the following procedure. Gearshift Knob - Push shifter boot down to expose clips on gearshift 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4876 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. Center Console Front Attaching Screws (Automatic) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4877 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 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. 6. Remove the center console/arm rest from the vehicle. 7. Lower park brake lever handle. Park Brake Lever Output Cable Adjustment Nut 8. Loosen adjusting nut on park brake lever output cable. This will take tension off output cable, allowing it to be easily removed from tension 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 9. Using a screwdriver unlatch the park brake output cable retainer. Then remove cable retainer from park brake cable tension equalizer. 10. Remove the park brake cable tension equalizer from the park brake lever output cable. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4878 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 ton 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. INSTALL 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 inch lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4879 2. Install the wiring harness on the park brake mechanism bracket. 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. 6. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 4880 Park Brake Lever Output Cable Adjustment - Tighten adjusting nut on park brake lever output cable until 12 mm millimeters of thread is out past top edge of adjustment nut. - 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. 10. Install the 2 screws attaching the front of the center console to the forward console. 11. Install screws attaching rear of center console assembly to console bracket. 12. Install the shifter boot or PRNDL plate back in the center console. 13. Install the shift knob on the shifter. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications GENERAL SPECIFICATIONS: Make/Type ........................................................................................................................................... .................................................... Bendix/Vacuum Mounting Studs .................................................... ................................................................................................................................................ M8x1.25 Type ...................................................................................................................................... .................................................................. 205 mm Tandem Boost At 20 inches of Manifold Vacuum ............................................................................................................................................................. 4690 All TIGHTENING SPECIFICATIONS: To Dash Panel Mounting Bolts ....................................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > With ABS Vacuum Brake Booster: Description and Operation With ABS Master Cylinder And Vacuum Booster A vehicle equipped with the Teves Mark 20 ABS (without traction control) uses a different master cylinder and power brake booster then a vehicle that is not equipped with antilock brakes. A vehicle equipped with ABS uses a center port master cylinder while a vehicle which is not equipped with ABS uses a compensating port master cylinder. The primary and secondary outlet ports on the master cylinder go directly to the Hydraulic Control Unit (HCU). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > With ABS > Page 4887 Vacuum Brake Booster: Description and Operation Without ABS All vehicles use a 205 mm tandem diaphragm power brake vacuum booster. The power brake 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. Power Brake Booster Identification The power brake booster can be identified if required, by the tag attached to the body of the booster assembly. This tag contains the following information: The production part number of the power booster assembly, the date it was built, who manufactured it, and brake sales code. NOTE: The power brake 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 power booster vacuum check valve is not repairable but can be replaced as an assembly. The power brake booster reduces amount of force required by the driver to obtain the necessary hydraulic pressure to stop vehicle. The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on the engine through the power brake booster check valve. Power Brake Booster Assembly As the brake pedal is depressed, the power boosters input rod moves forward. This opens and closes valves in the power 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 power 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > With ABS > Page 4888 Different systems and engine combinations require different vacuum hose routings. The power brake 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 power booster to the intake manifold. The master cylinder is bolted to the front of the power brake vacuum booster assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. Speed Control Servo Attachment 3. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4891 Purge Control Solenoid 4. Remove the vacuum harness connector and electrical connector from the purge solenoid. Remove purge solenoid from vehicle. Vacuum Hose Attachment To Check Valve 5. Remove the vacuum hoses from the check valve located on the power brake vacuum booster. EGR Valve Transducer Assembly 6. Remove EGR valve transducer assembly and vacuum hoses from the EGR valve. Valve removal is necessary for required clearance to remove power brake vacuum booster from vehicle and not damage transducer during removal. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4892 Master Cylinder Brake Fluid Level Sensor 7. Remove the vehicle's wiring harness connector from the master cylinder brake fluid level sensor. Master Cylinder Mounting To Vacuum Booster 8. Remove the 2 nuts attaching the master cylinder assembly to the power brake vacuum booster. Master Cylinder Assembly Positioned For Booster Removal 9. Without removing the brake tubes from master cylinder, remove it from the power brake vacuum booster. Then carefully lower master cylinder and brake tubes as an assembly until it is positioned on top of the transaxle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4893 Input Rod Retaining Pin 10. 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 11. 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 12. Slide power brake vacuum booster forward until mounting studs clear dash panel and then tilt up and rotate toward center of vehicle to remove. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4894 Vacuum Brake Booster: Service and Repair Installation 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 inch 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. 5. 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 6. Install the 2 master cylinder to power brake unit mounting nuts. Tighten the 2 mounting nuts to a torque of 28 Nm (250 inch lbs.). 7. Install the vehicle's wiring harness connector on the master cylinder brake fluid level sensor. Purge Control Solenoid Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4895 8. Install the purge control solenoid on the left front frame rail. Tighten the purge control solenoid mounting bolt. EGR Valve Transducer Assembly 9. Install the EGR transducer assembly on the EGR valve. Install the vehicle wiring harness connector on the EGR transducer, ensuring the retaining clip is fully engaged with transducer. Vacuum Hose Attachment To Check Valve 10. Connect all previously removed vacuum hoses onto the power brake vacuum booster check valve. Speed Control Servo Attachment 11. 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 inch lbs.). 12. Check brake light switch for correct adjustment. If required, adjust stop lamp switch as necessary. Refer to Lighting and Horns Brake Light Switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 4896 13. Road test vehicle to ensure proper operation of the vehicles brake system Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES Fuse Locations In Power Distribution Center The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center (PDC). The PDC is located on the drivers side of the engine compartment forward of the strut tower. ABS RELAYS On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will need to be replaced. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Controller Antilock Brakes To HCU Mounting Bolts ............................................................................................................................. 2 Nm (17 inch lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 4904 Electronic Brake Control Module: Locations ICU Mounting Location Mounted on the crossmember over the steering gear on the right side. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 4905 Controller Antilock Brakes Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 4906 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock Brake System (ABS) amber warning lamp. The primary functions of the CAB are to: - detect wheel locking tendencies - control fluid pressure modulation to the brakes during antilock stop - monitor the system for proper operation - provide communication to the DRB while in diagnostic mode - store diagnostic information in non-volatile memory The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB for proper operation If the CAB detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp. If the antilock function is disabled, the system will revert to standard base brake system operation. CAB Inputs Include The Following: - ABS Warning Lamp - Diagnostic Communication - Four Wheel Speed Sensors - Ignition Switch - Fused B+ - Stop Lamp Switch CAB Outputs Include The Following: - ABS Warning Light Actuation - Voltage - Eight Valves - Diagnostic Communication - Body Controller Communication Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 4907 Electronic Brake Control Module: Service and Repair REMOVE NOTE: To replace the Controller Antilock Brakes (CAB) on this vehicle, the Integrated Control Unit (ICU) and CAB need to be removed from the vehicle as a unit. The CAB can then be separated from the Hydraulic Control Unit (HCU). Do not attempt to replace the CAB with the ICU mounted in the vehicle. 1. Remove the ICU from the vehicle. Pump Motor To CAB Wiring Harness 2. Unplug the pump motor wiring harness from the CAB. CAB Attaching Bolts 3. Remove the 4 bolts attaching the CAB to the HCU. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 4908 Remove/Install CAB 4. Remove the CAB from the HCU. INSTALL 1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU. 5. Bleed the base brakes and the ABS brakes hydraulic system. 6. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp circuit. This switch does not disable the ABS system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 4913 Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the 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 the retaining tabs on the end of the brake fluid level sensor. Removing Fluid Level Switch From Reservoir Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 4914 3. While compressing retaining tabs, grasp opposite end of brake fluid level sensor and pull it out of master cylinder fluid reservoir. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Resistance 2,160 - 2,640 ohms Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 4919 Wheel Speed Sensor: Mechanical Specifications Total Indicator Run Out Allowed 0.006 in Front Rear Air Gap 0.007 - 0.072 in 0.015 - 0.059 in Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 4922 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 4925 Wheel Speed Sensor: Diagrams Rear Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 4926 Wheel Speed Sensor: Testing and Inspection CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tonewheels 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 Tonewheel Runout in the Specification Section in this section of the service manual for the tonewheel runout specification. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect tonewheels for looseness on their mounting surfaces. Tonewheels 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. Refer to Wheel Speed Sensor Clearance in the Specification Section in this section of the service manual. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 REMOVE 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4929 Speed Sensor Head Attachment To Steering Knuckle 5. Remove bolt attaching speed sensor to 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. INSTALL 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 shown ay result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the wheel speed sensor cable connector to the vehicle wiring harness. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4930 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 as shown. 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.). 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 pin. Use Mopar, Multi-Purpose Grease or an equivalent on speed sensor head locating pin. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4931 Wheel Speed Sensor: Service and Repair Rear REMOVE 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 4932 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 from the rear brake support plate. INSTALL 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. 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 (76 inch lbs.). 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. 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. 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. 9. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Left Front Of Impact Beam Below Grille, Battery Temperature Sensor, Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4938 Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4939 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4940 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 4943 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4953 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4954 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 (L4-2.4L VIN X (1998)) 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 4955 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 (L4-2.4L VIN X (1998)) 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 4956 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 (L4-2.4L VIN X (1998)) 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 4957 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 (L4-2.4L VIN X (1998)) 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 4958 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 (L4-2.4L VIN X (1998)) 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 4959 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 (L4-2.4L VIN X (1998)) 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 4960 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 (L4-2.4L VIN X (1998)) 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 4961 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 (L4-2.4L VIN X (1998)) 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 4962 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 (L4-2.4L VIN X (1998)) 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 4963 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 (L4-2.4L VIN X (1998)) 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 4964 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 4970 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 4971 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 (L4-2.4L VIN X (1998)) 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 4972 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 (L4-2.4L VIN X (1998)) 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 4973 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 (L4-2.4L VIN X (1998)) 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 4974 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 (L4-2.4L VIN X (1998)) 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 4975 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 (L4-2.4L VIN X (1998)) 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 4976 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 (L4-2.4L VIN X (1998)) 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 4977 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 (L4-2.4L VIN X (1998)) 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 4978 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 (L4-2.4L VIN X (1998)) 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 4979 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 (L4-2.4L VIN X (1998)) 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 4980 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 (L4-2.4L VIN X (1998)) 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 4981 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4982 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4983 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4984 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations Power Distribution Center Starter Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Component Locations > Page 4990 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4991 Power Distribution Center Starter Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4992 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 88A and 30, and no continuity between terminals 88 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 85 ± 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 88 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 Starting and Charging/Starting System/Ignition Switch/Testing and Inspection/Procedures. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Left Front Of Impact Beam Below Grille, Battery Temperature Sensor, Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4997 Battery Temperature Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4998 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4999 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 5002 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications Generator: Electrical 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications > Page 5008 Generator: Mechanical Specifications DESCRIPTION = TORQUE Battery Terminal Nut = 10 N.m (90 in. lbs.) Battery Hold Down Clamp Bolt = 10 N.m (90 in. lbs.) Battery Negative Cable Nut at Shock Tower = 10 N.m (90 in. lbs.) Generator B+ Terminal = 9 N.m (75 in. lbs.) Generator Mounting Bolt = 54 N.m (40 ft. lbs.) Generator Pivot Bolt = 54 N.m (40 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5009 Generator Field Connector, Engine Wiring Harness, A/C Clutch Conn.,A/C Pressure Transducer Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5010 Generator Field Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5011 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5012 Generator: Service and Repair REMOVAL Battery Cable At Shock Tower 1. Disconnect battery negative cable from remote negative terminal on shock tower. 2. Unplug field circuit from generator. 3. Remove B+ terminal cover by spreading the cover with a small flat blade tool. Generator 4. Remove the B+ terminal nut and wire. 5. Loosen adjusting T-bolt, but do not remove. 6. Loosen pivot bolt, but do not remove. 7. Loosen adjusting bolt to allow removal of the generator drive belt. 8. Remove adjusting T-bolt. 9. Remove pivot bolt. 10. Remove ABS braking unit by removing the two lower plate mounting bolts. 11. Remove Coolant Overflow bottle. 12. Remove by sliding alternator under the air conditioning lines towards passenger side of vehicle. 13. Remove generator from vehicle. INSTALLATION 1. For installation, reverse above procedures. Tighten all fasteners to the proper torque. Refer to the Torque Specifications chart. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5026 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5027 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 (L4-2.4L VIN X (1998)) 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 5028 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 (L4-2.4L VIN X (1998)) 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 5029 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 (L4-2.4L VIN X (1998)) 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 5030 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 (L4-2.4L VIN X (1998)) 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 5031 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 (L4-2.4L VIN X (1998)) 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 5032 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 (L4-2.4L VIN X (1998)) 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 5033 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 (L4-2.4L VIN X (1998)) 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 5034 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 (L4-2.4L VIN X (1998)) 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 5035 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 (L4-2.4L VIN X (1998)) 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 5036 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 (L4-2.4L VIN X (1998)) 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 5037 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5043 A. Load Limiting Push Rod Packages Each package contains one load limiting push rod and return spring assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5044 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 (L4-2.4L VIN X (1998)) 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 5045 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 (L4-2.4L VIN X (1998)) 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 5046 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 (L4-2.4L VIN X (1998)) 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 5047 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 (L4-2.4L VIN X (1998)) 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 5048 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 (L4-2.4L VIN X (1998)) 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 5049 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 (L4-2.4L VIN X (1998)) 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 5050 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 (L4-2.4L VIN X (1998)) 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 5051 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 (L4-2.4L VIN X (1998)) 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 5052 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 (L4-2.4L VIN X (1998)) 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 5053 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 (L4-2.4L VIN X (1998)) 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 5054 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5055 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5056 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5057 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Automatic Transaxle Starter Motor: Service and Repair Automatic Transaxle REMOVAL Remove Remote Battery At Shock Tower 1. Disconnect battery negative cable from remote negative terminal on shock tower. 2. Remove air cleaner resonator. 3. Remove three Transmission Control Module (TCM) mounting screws. Move TCM to provide access to top starter mounting bolt. DO NOT disconnect TCM wiring. Wire Terminal Connection 4. Remove top bolt attaching starter to transmission housing. 5. Raise vehicle. 5. Remove battery positive cable nut from starter and remove cable. 7. Disconnect push on solenoid connector. Unlock the red locking tab and compress lock to release the connector. 8. Remove the bottom bolt attaching starter to transmission housing. 9. Remove starter from vehicle. INSTALLATION 1. With vehicle is raised, set starter face into transmission housing. 2. Lower vehicle. 3. Install top starter mounting bolt but do not tighten. 4. Raise vehicle. 5. Install bottom starter mounting bolt and tighten to 54 Nm (40 ft. lbs.) torque. 5. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Automatic Transaxle > Page 5062 7. Connect battery positive cable to solenoid post. 8. Connect the push-on solenoid connector. 9. Lower vehicle. 10. Tighten top starter bolt to 54 N.m (40 ft. lbs.) torque. 11. Install TCM and the mounting screws. 12. Install air cleaner resonator. 13. Connect battery remote cable to the remote terminal. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Automatic Transaxle > Page 5063 Starter Motor: Service and Repair Manual Transaxle REMOVAL Remove Remote Battery At Shock Tower 1. Disconnect battery negative cable from remote negative terminal on shock tower. 2. Remove air cleaner resonator. 3. Remove three Transmission Control Module (TCM) mounting screws. Move TCM to provide access to top starter mounting bolt. DO NOT disconnect TCM wiring. Wire Terminal Connection 4. Remove top bolt attaching starter to transmission housing. 5. Raise vehicle. 5. Remove battery positive cable nut from starter and remove cable. 7. Disconnect push on solenoid connector. Unlock the red locking tab and compress lock to release the connector. 8. Remove the bottom bolt attaching starter to transmission housing. 9. Remove starter from vehicle. INSTALLATION 1. With vehicle is raised, set starter face into transmission housing. 2. Lower vehicle. 3. Install top starter mounting bolt but do not tighten. 4. Raise vehicle. 5. Install bottom starter mounting bolt and tighten to 54 Nm (40 ft. lbs.) torque. 5. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Automatic Transaxle > Page 5064 7. Connect battery positive cable to solenoid post. 8. Connect the push-on solenoid connector. 9. Lower vehicle. 10. Tighten top starter bolt to 54 N.m (40 ft. lbs.) torque. 11. Install TCM and the mounting screws. 12. Install air cleaner resonator. 13. Connect battery remote cable to the remote terminal. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Component Locations Power Distribution Center Starter Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Component Locations > Page 5069 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5070 Power Distribution Center Starter Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5071 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 88A and 30, and no continuity between terminals 88 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 85 ± 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 88 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 Starting and Charging/Starting System/Ignition Switch/Testing and Inspection/Procedures. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5098 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center Power Distribution Center: Diagrams Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5103 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5104 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5105 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5106 Power Distribution Center: Diagrams Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5107 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5108 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 5113 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 5114 Fuse: Locations Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 5115 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 5116 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5121 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5122 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5123 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5124 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5125 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5126 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5127 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5128 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center Fusible Link: Locations Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center > Page 5133 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center > Page 5134 Fusible Link: Locations Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center > Page 5135 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center > Page 5136 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Multiple Junction Connector: Connector Views Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Multiple Junction Connector: Electrical Diagrams Diagrams Junction Block (Part 1 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 Junction Block (Part 2 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 Junction Block (Part 3 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 Junction Block (Part 4 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 Junction Block (Part 5 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 Junction Block (Part 6 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 Junction Block (Part 7 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 Junction Block (Part 8 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 Junction Block (Part 9 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 Junction Block (Part 10 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 Junction Block (Part 11 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Junction Block (Part 12 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations ABS Fuses Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5182 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5183 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5184 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5185 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5186 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5187 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations ABS Fuses Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5193 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5194 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5195 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5196 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5197 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5198 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5222 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center Power Distribution Center: Diagrams Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5227 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5228 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5229 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5230 Power Distribution Center: Diagrams Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5231 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Power Distribution Center > Page 5232 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 5237 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 5238 Fuse: Locations Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 5239 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 5240 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5245 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5246 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5247 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5248 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5249 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5250 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5251 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5252 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center Fusible Link: Locations Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center > Page 5257 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center > Page 5258 Fusible Link: Locations Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center > Page 5259 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Power Distribution Center > Page 5260 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 Multiple Junction Connector: Connector Views Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 Multiple Junction Connector: Electrical Diagrams Diagrams Junction Block (Part 1 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 Junction Block (Part 2 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 Junction Block (Part 3 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 Junction Block (Part 4 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 Junction Block (Part 5 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 Junction Block (Part 6 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Junction Block (Part 7 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 Junction Block (Part 8 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 Junction Block (Part 9 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 Junction Block (Part 10 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5295 Junction Block (Part 11 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5296 Junction Block (Part 12 Of 13) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5297 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations ABS Fuses Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5306 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5307 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5308 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5309 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5310 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5311 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations ABS Fuses Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5317 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5318 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5319 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5320 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5321 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 5322 Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 +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 ......................................................................................................... .................................................................................... + or -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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > General Information > Page 5329 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5330 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5331 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 5332 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5339 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5340 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5341 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5342 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service Precautions > Page 5347 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5350 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5351 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5352 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5353 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5354 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5355 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 22 Nm (16 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5356 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 244 Nm (180 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5366 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5372 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 (L4-2.4L VIN X (1998)) 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 5373 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5374 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5379 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5385 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 (L4-2.4L VIN X (1998)) 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 5386 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5387 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5388 Power Steering Fluid: Specifications The recommended lubricant is Mopar Power Steering Fluid. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5389 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications Power Steering Fluid Reservoir: Specifications Reservoir To Mounting Bracket Or Engine .............................................................................................................................................. 28 Nm (21 ft. lbs.) Reservoir Bracket To Engine ............................................................................................. ....................................................................... 28 Nm (21 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 5396 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Tube Nuts ............................................................................................................................................ ................................................ 31 Nm (275 inch lbs.) Banjo Fitting Flow Bolt ..................................... ....................................................................................................................................... 47 Nm (33 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 (L4-2.4L VIN X (1998)) 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 Fig. 7 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. 2. Remove the tie-strap holding the power steering fluid supply hose to the power steering pressure hose. 3. Remove hose clamp, attaching power steering fluid supply hose to power steering fluid reservoir. Then remove power steering fluid supply hose from power steering fluid reservoir. 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. 5. Remove power steering fluid supply hose from engine. INSTALL 1. Install power steering fluid supply hose back on engine making sure it is correctly routed. 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. 2. Install power steering fluid supply hose on power steering fluid reservoir fitting. Install hose clamp on power steering fluid supply hose at power steering fluid reservoir. Be sure hose clamp is installed on return hose past upset bead on power steering fluid reservoir. 3. Install power steering fluid supply hose on power steering pump fitting. 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. CAUTION: The tie strap must be installed on the power steering pressure hose and supply hose to ensure proper routing of the hoses. 4. Install the tie-strap holding the power steering fluid supply hose to the power steering pressure hose. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 5. Fill power steering fluid reservoir. 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 (L4-2.4L VIN X (1998)) 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 5402 14. After hose is installed, check for leaks at all hose connections. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5403 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5404 4. Remove power steering pressure hose routing bracket from the power steering return hose bracket on rear of engine. Then remove the nut attaching the power steering pressure hose routing bracket to stud on side of cylinder head. 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 (L4-2.4L VIN X (1998)) 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 5405 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 (L4-2.4L VIN X (1998)) 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 5406 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 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 (L4-2.4L VIN X (1998)) 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 5407 6. Remove power steering pressure hose routing bracket from the power steering return hose routing bracket on rear of engine. Then remove the bolt attaching the power steering pressure hose routing bracket to the cylinder head. 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 (L4-2.4L VIN X (1998)) 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 5408 7. Install power steering return hose routing bracket on rear of cylinder head and securely tighten bolt. Then install the power steering pressure hose routing bracket on the return hose routing bracket and securely tighten attaching bolt. 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 (L4-2.4L VIN X (1998)) 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 5409 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. Hose Clamps At Power Steering Fluid Cooler 6. Remove the hose clamps from the power steering fluid hoses. Drain power steering fluid from the hoses and the power steering fluid cooler. Power Steering Cooler Line Attachment Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5410 7. Remove the bracket attaching the power steering fluid cooler lines to the left front frame rail. 8. Lower the front suspension crossmember. 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. Power Steering Cooler Line Attachment Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5411 2. Install the cooler lines in the routing clip on the left frame rail. 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. Torquing Power Steering Fluid Hose Tube Nuts 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.). Hose Clamps At Power Steering Fluid Cooler Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5412 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. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5421 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 (L4-2.4L VIN X (1998)) 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 5422 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5423 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5428 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5434 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5440 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 (L4-2.4L VIN X (1998)) 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 5441 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5442 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5445 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Flow At 1500 RPM & Min. Pressure ........................................................................................................................... 4.9 - 5.3 Liters/Min (1.3 - 1.4 GPM) Control Valve Pressure Relief ......................................................................................................................................... 8240 - 8920 kPa (1195 - 1293 psi) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5446 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. Vehicles that are equipped with the standard nonvariable power steering use a constant flow rate and displacement vane type power steering pump. Vehicles that are equipped with variable assist power steering use a droop flow power steering pump. The droop flow power steering pump is a constant displacement but variable flow rate vane type power steering pump. This power steering pump provides the speed-sensitive variable-assist power steering. 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 mounted to the rear of the cylinder head on the passenger side of the vehicle. 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 (L4-2.4L VIN X (1998)) 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. Fig. 2 REMOVAL 1. Remove the power steering fluid pressure hose from power steering pump pressure fitting. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5449 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 (L4-2.4L VIN X (1998)) 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 5450 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 (L4-2.4L VIN X (1998)) 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 5451 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 (L4-2.4L VIN X (1998)) 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 5452 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 (L4-2.4L VIN X (1998)) 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 5453 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 (L4-2.4L VIN X (1998)) 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 5454 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 (L4-2.4L VIN X (1998)) 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 5455 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. Fig. 2 REMOVAL 1. Remove the power steering fluid pressure hose from power steering pump pressure fitting. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5456 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5457 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 (L4-2.4L VIN X (1998)) 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 5458 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5459 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 (L4-2.4L VIN X (1998)) 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 5460 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. Installation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5461 Fig. 14 1. Install power steering pump and mounting bracket as an assembly back in vehicle, using reverse order of removal. 2. Place the power steering pump on top of the antilock brakes hydraulic control unit. Fig. 13 3. Install the power steering pump mounting bracket on the rear of the engine. Tighten the mounting bracket attaching bolts to a torque of 54 Nm (40 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5462 Fig. 6 4. Install power steering pump and front bracket on the cast aluminum engine bracket. Loosely install the bolt at the adjusting slot. Fig. 7 5. Loosely install the bolt mounting the power steering pump to its rear mounting bracket. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5463 Fig. 11 Fig. 11 Top Bolt For Power Steering Pump Mounting Bracket 6. Loosely install bolt attaching top of power steering pump front bracket to the cast aluminum accessory drive bracket. Access to install the bolt is through the wheel speed sensor cable routing hole. 7. Using a lint free towel, wipe clean all open power steering hose ends, and power steering pump fittings. 8. Install a new O-ring on end of power steering pressure hose fitting. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5464 9. If vehicle is equipped with variable-assist power steering, install a new O-ring on the end of the power steering pressure hose banjo fitting. 10. If vehicle is equipped with variable-assist power steering, install a new O-ring on the banjo fitting bolt for the power steering pressure hose banjo fitting. 11. Lubricate all O-rings using fresh clean power steering fluid. 12. Install the power steering pressure hose on 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. 13. Install power steering pump drive belt on power steering pump pulley. 14. Install a 1/2 inch breaker bar in the square adjusting hole in the front power steering pump mounting bracket. Then using breaker bar rotate power steering pump to obtain the correct drive belt tension. Refer to Engine for the correct drive belt tension specification. 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.). Access to tighten and torque the bolt is through the wheel speed sensor cable routing hole. 15. Position power steering pressure hose, so hose is not contacting the power steering pump pulley or the drive belt. a. If vehicle is equipped with a standard tube nut on the power steering fluid pressure hose tighten the tube nut to a torque of 31 Nm (275 inch lbs.). b. If vehicle is equipped with a banjo fitting on the power steering fluid pressure hose tighten the banjo fitting bolt a torque of 34 Nm (25 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5465 . Fig. 2 16. Install power steering fluid supply hose of power steering pump suction fitting. Install hose clamp on hose. Be sure hose clamp is installed on hose past upset bead on suction fitting. 17. Install heat shield on hydraulic control unit for the antilock brake system. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5466 Fig. 9 18. Route the wiring harness connector for the wheel speed sensor cable through hole in inner fender. Connect vehicle wiring harness to wheel speed sensor cable. Fig. 8 19. On a vehicle equipped with antilock brakes, install wheel speed sensor cable sealing grommet in routing hole. Install retainer for wheel speed sensor cable grommet on right inner fender. 20. On a vehicle not equipped with antilock brakes, install sealing plug back in routing hole. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5467 Accessory Drive Splash Shield 21. Install accessory drive splash shield. 22. Install wheel and tire. 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.). 23. Lower vehicle. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar (R), Power Steering Fluid, or equivalent. 24. Fill power steering reservoir to correct fluid level. 25. Connect negative cable back on negative pot of battery. 26. Start the engine and let run for a few seconds Then turn the engine off. 27. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 28. Raise front wheels of vehicle off the ground. 29. Start engine, then slowly turn steering wheel right and left several times until lightly contacting the wheel stops. Then turn the engine off. 30. Add power steering fluid if necessary. 31. Lower the vehicle. Start engine again and turn the steering wheel slowly from lock to lock. 32. Stop the engine. Check the fluid level and refill as required. 33. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 34. After power steering pump is installed, check for leaks at all hose connections and power steering pump fittings. Removal NOTE: This vehicle is equipped with two different power steering pumps. The type of power steering pump used depends on what type of power steering system the vehicle is equipped with. The standard steering system uses a constant flow rate power steering pump. The variable-assist power steering system uses a variable flow rate power steering pump. The external difference between the two power steering pumps is the type of fitting used on the power steering fluid pressure hose connection to the power steering pump. The constant flow rate power steering pump uses a standard tube nut fitting at the power steering pump. The variable flow rate power steering pump uses a banjo type fitting at the power steering pump. The removal and installation procedures for both power steering pumps though is the same. 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. Raise vehicle. 4. Remove right front tire and wheel. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5468 Accessory Drive Splash Shield 5. Remove accessory drive splash shield. Fig. 2 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5469 6. Remove the power steering fluid pressure hose from the pressure fitting on power steering pump. Let remaining power steering fluid drain out of the 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. 7. Remove hose clamp, attaching power steering fluid supply hose to the power steering pump suction fitting. Then remove power steering fluid supply hose from fitting. Install a cap on suction fitting of power steering pump. 8. Remove the heat shield for the antilock brakes hydraulic control unit. Fig. 6 9. Remove bolt at adjustment slot, attaching front power steering pump mounting bracket to cast aluminum accessory drive bracket on engine. Fig. 7 10. Remove bolt attaching the back of the power steering pump to the cast aluminum mounting bracket. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5470 Fig. 8 11. Remove retainer for wheel speed sensor cable grommet from right inner fender. Fig. 9 12. Remove speed sensor cable sealing grommet from inner fender. Disconnect the wheel speed sensor cable from the vehicle wiring harness. Push vehicle wiring harness back through hole in inner fender and unclip wiring harness through hole in inner fender. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5471 Cable Routing Hole Sealing Plug 13. If vehicle is not equipped with antilock brakes, just a sealing plug will be installed in the wheel speed sensor cable routing hole. Remove the sealing plug from the hole. Fig. 11 Fig. 11 Top Bolt For Power Steering Pump Mounting Bracket Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5472 14. Remove bolt attaching top of power steering pump front bracket to the cast aluminum mounting bracket. Access to the top bolt is through the wheel speed sensor cable routing hole. To access the bolt use a long extension and a 15 mm flex socket. 15. Remove power steering pump drive belt from power steering pump pulley. NOTE: The power steering pump can not be removed from the vehicle without first removing the power steering pump mounting bracket from the engine. 16. Remove power steering pump and its front mounting bracket as an assembly from the engine mounted power steering pump mounting bracket. Place the power steering pump on top of the antilock brakes hydraulic control unit. Fig. 13 17. Remove the power steering pump mounting bracket from the rear of the engine. Fig. 14 18. Remove power steering pump and front mounting bracket as an assembly from the engine and vehicle. Pump and mounting bracket is removable by bringing it out through the area between frame, rear of engine, driveshaft and front suspension crossmember. 19. Transfer required parts from removed power steering pump, to replacement power steering pump. Suction Port Fitting Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 5473 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 5479 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5480 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5481 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 5482 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5489 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming NOTE: A DRB scan tool is required for diagnosis of the airbag system. Refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures for more information. ARMING 1. Make sure no one is in the vehicle. 2. Connect battery negative terminal. 3. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 4. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 5. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 6. Using the scan tool, read and record the active diagnostic trouble code data. 7. Read and record any stored diagnostic trouble codes. 8. Refer to the proper Passive Restraint Diagnostic Test if any diagnostic trouble codes are found in Step 6 and Step 7. 9. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Air Bags 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 Air Bags to diagnose the problem. To test the airbag warning lamp operation in the cluster only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications To Suspension Crossmember Bolts .......................................................................................................................................................... 68 Nm (50 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5496 Steering Gear: Description and Operation 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5499 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, or equivalent. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5500 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5501 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5502 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5503 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5504 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5505 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5506 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5507 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5508 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5509 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. 18. Fill power steering pump fluid reservoir to the (Full-Cold) proper level. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5510 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5511 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5520 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5526 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5527 Steering Wheel: Specifications Retaining Nut ....................................................................................................................................... ..................................................... 61 Nm (45 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 5528 Steering Wheel: Service and Repair REMOVAL 1. Adjust the steering wheel so that the tires are in the straight ahead position. 2. Disconnect and isolate the battery negative remote cable. 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 the 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 airbag module mounting bracket. Remove the speed control wires from under the bracket and from the wire guides. 6. Remove the steering wheel retaining nut. 7. Remove the steering wheel with wheel puller tool. Carefully feed all of the wires through the steering wheel armature to avoid damaging wires. INSTALLATION 1. Ensure that the road wheels are in the straight ahead position. 2. Ensure that the clockspring is centered by using the centering indicator. Refer to Clockspring Centering Procedure. 3. Ensure that the turn signal stalk is in the neutral position. 4. 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. a. Ensure that the driving key on the steering wheel hub lines up with the slot in the clockspring rotor. b. Ensure that the block tooth in the steering wheel hub lines up with the missing tooth on the steering wheel shaft. 5. 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 bolts to 1.7 ± 1 N.m (15 ± 10 in. lbs.) torque. 6. Connect the horn lead to steering wheel. 7. Connect the yellow airbag lead to the Driver Airbag Module and push secondary latch into place. Check that the wires do not get pinched during installation. 8. Install the airbag module bolts and tighten the left side first. Tighten to 9 to 10 N.m (80 to 90 in. lbs.) torque. 9. Do not connect battery negative remote cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 5543 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 5544 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 5547 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 5548 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint Ball Joint: Specifications Lower Ball Joint FRONT: Castle Nut ............................................................................................................................................ ................................................. 74 Nm (55 ft. lbs.) Knuckle To Ball Stud Nut ..................................... ............................................................................................................................... 95 Nm (70 ft. lbs.) REAR: Castle Nut ............................................................................................................................................ ................................................. 67 Nm (50 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint > Page 5554 Ball Joint: Specifications Upper Ball Joint Castle Nut ............................................................................................................................................ ..................................................... 61 Nm (45 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Lower Ball Joint > Page 5557 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 5560 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 (L4-2.4L VIN X (1998)) 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. - The ball joint used in the lower control arm of this vehicle is a lubricated for life ball joint. This ball joint does not require any additional lubrication for the life of the vehicle. Do not alter the lower control arm or ball joint in an attempt to lubricate the lower control arm ball joint. If it is determined that the ball joint is lacking proper lubrication, the lower control arm will need to be replaced. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5563 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5564 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5565 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5566 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement > Page 5567 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5573 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5574 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Lower Control Arm Front Isolator Bushing > Page 5575 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications Cross-Member: Specifications FRONT: To Body Attaching Bolts ...................................................................................................................... ............................................ 163 Nm (120 ft. lbs.) REAR: To Body Attaching Bolts ...................................................................................................................... ................................................ 95 Nm (70 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications > Page 5579 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5582 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5583 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5584 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. NOTE: When installing the lateral links on the crossmember, the lateral link attaching bolts must be installed as listed below. Install the forward lateral link to crossmember bolts so that the head of the bolt will be toward the front of the vehicle when the crossmember is installed. Install the rear lateral link to crossmember bolts so that the threaded end of the bolt will be facing toward the front of the vehicle when the crossmember is installed. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5585 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5586 8. Install muffler support bracket on rear frame rail. Install rear exhaust pipe hanger on rear suspension crossmember. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Removal > Page 5587 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service Precautions > Page 5591 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5594 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5595 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5596 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5597 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5598 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5599 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 22 Nm (16 ft. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5600 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 244 Nm (180 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 5604 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 5605 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 (L4-2.4L VIN X (1998)) 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. Tighten the stabilizer bar attaching link to a torque of 32 Nm (24 ft. lbs.). 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Forward Lateral Link Replacement > Page 5608 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5614 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5615 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5616 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5617 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. Trailing Link Bushing And Retainer Installation 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5618 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Removal > Page 5619 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications Stabilizer Bushing: Specifications FRONT: Bushing Clamp Bolts ........................................................................................................................... ................................................. 61 Nm (45 ft. lbs.) REAR: Isolator Bushing Retainer Bolt ............................................................................................................................................................. 28 Nm (20 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications > Page 5624 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications FRONT: Attaching Nuts (All) .............................................................................................................................. ............................................. 105 Nm (78 ft. lbs.) REAR: Attaching Link Nut ............................................................................................................................... ................................................ 32 Nm (24 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 5628 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Front > Page 5633 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Page 5634 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 5640 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front > Page 5643 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5646 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5647 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5648 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5649 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5650 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5651 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. Compressing Shock Absorber Coil Spring 3. Compress shock absorber coil spring, using Pentastar Service Equipment Spring Compressor 7521-A, or equivalent. Be sure the spring compressor is fitted with a top and bottom attachment shoe that correctly fit the coil spring used on this shock absorber. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5652 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5653 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5654 Shock Absorber Dust Shield 11. Remove the dust shield from the shock absorber assembly. Shock Absorber Coil Spring And Compressor 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5655 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. Install the pinch bolt in the clevis bracket. Tighten the pinch bolt to a torque of 95 Nm (70 ft. lbs.). 2. Then using the clevis bracket, clamp the shock absorber assembly in a vise, with shock absorber in a vertical position. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5656 3. 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. 4. Install jounce bumper on rod of shock absorber assembly. 5. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5657 Shock Absorber Coil Spring And Compressor 6. 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. Shock Absorber Dust Shield 7. Install dust shield on rod of shock absorber assembly. 8. Install bottom washer on rod of shock absorber assembly and on top of dust shield. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5658 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. 9. Install the lower isolator bushing and sleeve in the shock absorber/lower control mounting bracket. Install coil spring upper isolator in mounting bracket. 10. Install the upper isolator bushing on the sleeve and the shock absorber/upper control arm mounting bracket. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5659 11. Install the shock absorber/upper control arm mounting bracket on the shock absorber assembly. 12. 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 is released from the coil spring. 13. 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.). 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. 15. 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. - Coil spring (Coil springs come in a standard and high rate be sure spring is replaced with a spring of the correct rate.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5660 - 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. Compressing Shock Absorber Spring 4. Compress shock absorber coil spring, using Pentastar Services Equipment Spring Compressor 7521-A or an equivalent. Be sure the spring compressor is fitted with a top and bottom attachment shoe that correctly fit the coil spring used on this shock absorber. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5661 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5662 8. Remove the isolator from the coil spring. Shock Absorber Rod Upper Washer 9. Remove the washer from the top of the dust shield and shock absorber rod. Shock Absorber Dust Shield 10. Remove the dust shield from the shock absorber assembly. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5663 Shock Absorber Coil Spring 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5664 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5665 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5666 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. Shock Absorber Coil Spring 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5667 Shock Absorber Dust Shield 7. Install dust shield on rod of shock absorber assembly. Shock Absorber Rod Upper Washer 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5668 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 5669 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5673 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5674 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5675 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 5676 not reverse the position of the inner and outer trailing link bushing or retainers on the trailing link. Trailing Link Bushing Installation INSTALL 1. Install the black 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, gold outer bushing retainer and nut on the trailing link. Using a large adjustable wrench on the flat of the trailing link to keep it from rotating, tighten the trailing link retaining nut to a torque of 99 Nm (73 ft. lbs.). 2. Install the (black) inner bushing retainer, and inner bushing on the trailing link. 3. 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. 4. 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 to a torque of 28 Nm (250 inch lbs.). CAUTION: When installing trailing link bushing retainers, retainers must be installed with cupped side of retainer facing away from bushing and knuckle. 5. Install the outer bushing, (gold) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5680 Wheel Bearing: Service Precautions CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result Do not use on pre-1998 model year vehicles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5681 Wheel Bearing: Description and Operation CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. 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 the diagnosis and testing section and the removal and installation section in this group of the service manual for the inspection and replacement of the rear wheel bearing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5682 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5683 Wheel Bearing: Service and Repair CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result Do not use on pre-1998 model year vehicles. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5684 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 129 Nm (95 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Driveshaft Nut ...................................................................................................................................... ................................................ 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information Wheels: Testing and Inspection General Information Inspect wheels for: - Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. Used wheels are not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 5699 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 5700 - 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 5701 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5705 Wheel Bearing: Service Precautions CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result Do not use on pre-1998 model year vehicles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5706 Wheel Bearing: Description and Operation CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. 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 the diagnosis and testing section and the removal and installation section in this group of the service manual for the inspection and replacement of the rear wheel bearing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5707 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5708 Wheel Bearing: Service and Repair CAUTION: If a vehicle is equipped with antilock brakes the tone wheels for the rear wheel speed sensors are pressed onto the hub. The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result Do not use on pre-1998 model year vehicles. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5709 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 129 Nm (95 ft. lbs.). 5. Lower vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Driveshaft Nut ...................................................................................................................................... ................................................ 244 Nm (180 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 5718 Wheel Fastener: Specifications Lug Nut Torque Lug Nuts .............................................................................................................................................. ................................. 109 - 150 Nm (80 - 110 ft. lbs.) Nut Hex Size .................................................... ........................................................................................................................................................... 19 mm Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 5719 Wheel Fastener: Specifications Wheel Stud Size Size ...................................................................................................................................................... ........................................................... M12 x 1.5 mm Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5720 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5721 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5722 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5723 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 5724 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 5730 Air Door Actuator / Motor: Service and Repair NOTE: If battery voltage is low or not sensed at the actuator/motor 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. Mode Door Motor Location The mode door actuator is located on the upper left side of the A/C- Heater housing. REMOVAL 1. Disconnect battery negative cable. 2. Remove left underpanel silencer/duct. Mode Motor Connector 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 (L4-2.4L VIN X (1998)) 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 The RECIRC door is actuated by a cable which mechanically positions the door. Recirculation Cable Location The RECIRC door actuator is located at the far right of the A/C Heater housing near the right A-pillar. REMOVAL 1. Place the ignition key in the OFF position before removing control module. Trim Bezel 2. Remove trim bezel. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Recirculation Door Cable Replacement > Page 5735 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Recirculation Door Cable Replacement > Page 5736 Discount 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 properly adjusted, free of interference and the 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 degree if the cable is properly adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Recirculation Door Cable Replacement > Page 5737 Air Door Cable: Service and Repair Temperature Control Cable Replacement 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. Suction Line Routing Clip 2. Remove trim bezel. Quick Connect Clip 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Recirculation Door Cable Replacement > Page 5738 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement Blower Motor: Service and Repair Blower Motor and Wheel Assembly Replacement 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. Blower Motor Wiring 3. Remove blower motor connector from resistor block. 4. Remove blower motor case retaining screws. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement > Page 5743 Blower Motor: Service and Repair Blower Motor Wheel Replacement REMOVAL AND INSTALLATION 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair Blower Motor Resistor: Service and Repair 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. Blower Motor Resistor 4. Pull blower motor resistor out of heater housing. INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications Compressor Clutch: Electrical Specifications DESCRIPTION Rated Voltage = 12 VDC Minimum Breakaway Torque = 31.4 N.m (23 ft. lbs., 3.2 Kgf.m) at 12VDC Minimum Engagement Voltage = 7.5 AT AIR GAP 0.5 mm REF Power Consumption = 50 WATTS MAX. Pulley Diameter = 110 mm DIA. (4.3 in.) Weight = 18.9 N.m (4.23 lbs, 1.92 Kgf) Clutch Type = Standard Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications > Page 5752 Compressor Clutch: Mechanical Specifications Clutch Air Gap ..................................................................................................................................... ...................................................... (0.013 - 0.025 in.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5753 Compressor Clutch: Description and Operation SYSTEM OPERATION 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5754 Compressor Clutch: Service and Repair REMOVAL 1. Remove the compressor from the mount. Compressor Shaft Nut Removal/Installation 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. 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5755 either part. This will result in clutch slippage due to insufficient contact area. INSTALLATION 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. Aligning Clutch Plate Splines 7. Install clutch plate on compressor shaft. Note the machined mating splines. 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 N.m (13 ft. lbs.) 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5756 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 (L4-2.4L VIN X (1998)) 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. 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 degree Celsius (70 degree Fahrenheit). 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Description and Operation Compressor Pulley: Description and Operation Clutch, Pulley and Coil They are mounted on the compressor providing a way to drive the compressor. The compressor clutch/ coil and manifold 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 dutch plate is magnetically engaged with the pulley and turns the compressor shaft. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5767 Power Distribution Center, A/C Clutch Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5768 Power Distribution Center, A/C Clutch Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5777 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 (L4-2.4L VIN X (1998)) 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 5778 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 5784 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 (L4-2.4L VIN X (1998)) 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 5785 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5786 Condenser HVAC: Description and Operation SYSTEM 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5787 Condenser HVAC: Service and Repair 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. 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 RECOVER 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 and cap A/C lines at the condenser. Grille Retainers 3. Remove grille retainers. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5788 Condenser Mounting 8. Remove condenser mounting bolts. CAUTION: Avoid bending or breaking condenser inlet tube when lifting condenser from the vehicle. Condenser Removal 9. Lift condenser from vehicle. INSTALLATION For installation, reverse above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5802 Control Assembly: Testing and Inspection 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 the proper Body Diagnostic Procedures. Testing Without Scan Tool. HVAC Control Module Connectors 1. Remove the control switch from console and do not disconnect control switch. 2. Using a ohmmeter, check leads between Pins 5 and 8 of the 8-way connector. Depress the rear window defogger button and the resistance reading should be 500 to 520 ohms. If not OK, replace HVAC. If OK, check: Rear window relay (EBL) - Blown fuse - Cut wire - Poor ground - Poor connection - Defective BCM - Bulkhead connector inoperative Switch Position = Ohm Range Panel = 828 to 856 Ohms Bi-Level = 1.279 to 1.315 K Ohms Floor = 2.302 to 2.358 K Ohms Mix = 5.202 to 5.318 K Ohms Defrost = 99.5 to 101.5 K Ohms Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 5803 Control Assembly: Service and Repair REMOVAL Center Bezel 1. Remove center bezel by pulling rearward to disengage four clips and remove attaching screws from cubby bin. 2. Remove the HVAC control attaching screws. Pull the control out to disconnect two electrical connectors and two control cables. Remove HVAC control. INSTALLATION - For installation, reverse the above procedures. The forward edge of bin must engage the forward console. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair Control Module HVAC: Service and Repair HVAC Control Module The control module is located below the radio. REMOVAL 1. Place the ignition key in the OFF position before removing control module. Control Module 2. Remove trim bezel. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Page 5807 6. Remove the control module retaining screws. 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 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. 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 1800 if the cable is properly adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Evaporator Coil Evaporator Core: Description and Operation Evaporator Coil SYSTEM 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Evaporator Coil > Page 5812 Evaporator Core: Description and Operation Evaporator Probe SYSTEM OPERATION 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 0.94 degree Celsius. (33.7 degree Fahrenheit). It is allowed to switch ON when the probe temperature reaches 2.05 degree Celsius. (35.7 degree Fahrenheit). The evaporator probe is located on the lower right side of the evaporator housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement Evaporator Core: Service and Repair Evaporator Core Replacement 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. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair A/C Housing 2. Remove A/C housing from vehicle. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 3. Remove recirculation door inlet cover. 4. Remove evaporator temperature probe. Housing Clips 5. Remove clips retaining evaporator housing to heater/distribution housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5815 Separate Housings Housings 6. Separate evaporator housing from heater/distribution housing. 7. Remove seal around evaporator tube inlet. Evaporator Housings Upper Cover 8. Remove evaporator housing upper cover. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5816 Remote Evaporator From Housings 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 For installation, reverse the above procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5817 Evaporator Core: Service and Repair Evaporator Probe Replacement REMOVAL 1. Disconnect battery. 2. Remove right under panel silencer/duct. Evaporator Probe Wiring 3. Disconnect wiring connector for evaporator probe. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Replacement > Page 5818 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. 2. Install evaporator probe access panel. 3. Connect probe wiring harness. 4. Reconnect battery. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams EVAP Temp Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 5822 Evaporator Temperature Sensor / Switch: Description and Operation SYSTEM OPERATION 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 0.94 degree Celsius. (33.7 degree Fahrenheit). It is allowed to switch ON when the probe temperature reaches 2.05 degree Celsius. (35.7 degree Fahrenheit). The evaporator probe is located on the lower right side of the evaporator housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation Expansion Valve: Description and Operation SYSTEM OPERATION 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 5826 Expansion Valve: Service and Repair WARNING: - AVOID BREATHING NC 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. Liquid Line Clip Suction Line Clip 2. Disconnect clips from expansion valve lines. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 5827 Special Tool 7240 For Liquid Line Special Tool 7242 For Suction Line 3. Use special tool kit 7193 to disconnect quick connectors on expansion valve. Lines At Expansion Valve 4. Remove lines at expansion valve. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 5828 Expansion Valve Bolts 5. Remove two retaining bolts from expansion valve. Expansion Valve 6. Remove expansion valve. 7. Remove expansion valve gasket. INSTALLATION CAUTION: Always install a new gasket when replacing expansion valve. - For installation, reverse the above procedures. Tighten new expansion valve to 11 N.m (100 in. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair 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 Heater-A/C Housing, Replacement. REMOVAL 1. Disconnect battery negative remote cable. Control Module 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair The heater hoses attach at the engine compartment cowl onto the heater core inlet/outlet and on the left side of the engine. The heater hoses are serviced separately of each other. The hoses can not be serviced with bulk roll heater hose. If it is necessary to replace a hose, use hose of the exact diameter and size and shape. The hoses are attached using spring tension clamps. REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Heater Hose Connection At Engine Heater Hose Connection At Heater Core 2. Using spring tension clamp pliers, remove clamps at each end of hose to be removed. 3. 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 (L4-2.4L VIN X (1998)) 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 SYSTEM OPERATION A/C Pressure Transducer The switch is located on the discharge line near the compressor. The pressure transducer functions as the refrigerant system pressure sensor. It supports the condenser/radiator fans and compressor functions. 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 screwed attached to a valve on the discharge line near the compressor. High Pressure Relief Valve 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation SYSTEM OPERATION 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 aluminum 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 NC 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. 2. Disconnect A/C pressure transducer wire harness. Quick Connect Clip Special Tool For Line At Condenser 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5843 Line At Compressor 4. Disconnect line at A/C compressor. Remove discharge line. INSTALLATION - For installation, reverse the above procedures. Tighten bolts to 22 N.m (200 in. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5844 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement TO EXPANSION VALVE REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. Liquid Line Clip At Expansion Valve 2. Remove A/C quick connect clip at expansion valve. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5845 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. TO CONDENSER REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. Clip Removal 2. Remove A/C quick connect clip at condenser. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5846 Quick Coupler Using Special Tool 7240 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. CAUTION: Cap all lines that are not being replaced and cap the condenser inlet. Liquid Line At Receiver/Drier 4. Disconnect liquid line from the receiver/drier. 5. Remove the liquid line from the vehicle. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5847 INSTALLATION For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5848 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL 1. Remove refrigerant from the A/C system using a refrigerant recovery machine. Suction Line Routing Clip 2. Remove suction line clip at right strut tower. Quick Connect Clip 3. Remove quick conned. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 5849 Suction Line At Compressor 4. Disconnect line at compressor end. 5. Remove suction line from vehicle. INSTALLATION - For installation, reverse the above procedures. Tighten bolts to 22 N.m (200 in. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly Housing Assembly HVAC: Service and Repair Heater-A/C Housing Disassembly and Assembly Heater-A/C housing must be removed from vehicle before performing this operation. Refer to Heater-A/C Unit Housing replacement. 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 Heater - A/C Unit Mode Motor Linkage 1. Place Heater-A/C unit assembly on workbench. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5854 Mode Motor 2. Remove A/C mode motor. Recirculation Air Inlet Recirculation Housing Removal 3. Remove upper recirculation air inlet housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5855 Rear Y - Cam Release 4. From inside of air inlet, depress release tang on rear inlet door. 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. Rear Air Inlet Door Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5856 10. Unsnap and remove rear air inlet door. 11. Front air inlet door and lever is serviced with recirculation housing. Blower Motor Wiring 12. Remove blower motor wiring at resistor. Blower Motor 13. Remove blower motor. Evaporator Probe Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5857 14. Using a flat blade pry tool, Pull up on tab at evaporator probe cover. Turn evaporator probe cover clockwise 90 degree. Evaporator Probe Needle 15. Remove evaporator probe cover. Pull evaporator needle from evaporator. Blower Motor Resistor 16. Remove blower motor resistor. Housing Clips 17. Remove clips retaining evaporator housing to heater/distribution housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5858 Separate Housings 18. Separate evaporator housing from heater/distribution housing. Evaporator Tube Inlet Seal 19. Remove seal around evaporator tube inlet. Evaporator Housing Upper Cover 20. Remove evaporator housing upper cover. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5859 Remote Evaporator From Housing 21. Lift evaporator out of lower housing. 22. Remove styrofoam seal around evaporator. Lower Floor Distribution Housing 23. Remove lower heat/distribution housing clips. Remove housing. Heater Core Cover Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5860 Heater Core Cover Removal 24. Remove heater core cover. Slide Out Core 25. Slide heater core out of heater housing. Temperature Door Lever Link 26. Remove temperature door lever link retaining screw. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5861 Temperature Door Lever Link Removal 27. Remove temperature door lever link. 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. Align Slots Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5862 Remove Lever Link 29. Turn floor door lever link until it aligns with slots cut into it. Remove floor door lever link. Mode Motor Cam Mode Motor Cam Removal 30. Remove mode motor cam from housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5863 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. Panel Door Lever Link 33. Line up slots on panel door lever link. Remove panel door lever link from housing. Defrost Door Lever Link 34. Unsnap defrost door lever link from housing. 35. Remove defrost door seal from housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5864 Front And Rear Housing Halves 36. Remove A/C housing rear cover half from front half. Defrost Door Removal 37. Remove defrost door from housing. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5865 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5866 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation REMOVAL The heater core may be removed without removing the unit housing. Refer to: "Heater Core : Service and Repair" See: Heater Core/Service and Repair 1. Disconnect battery negative remote cable. This must be done to prevent accidental air bag deployment. 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. 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 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. Refer to A/C line replacement 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. Trim Bezel 7. Remove trim bezel. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5867 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Disassembly and Assembly > Page 5868 30. Remove bolts at lower A-posts. 31. Remove instrument panel frame and wiring. 32. Remove bolts securing Heater-A/C housing to cowl. INSTALLATION - For installation, reverse the above 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 degree if the cable is properly adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation SYSTEM OPERATION The drier is used to remove any traces of moisture from the refrigerant system. The filter is used to separate any foreign particles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 5872 Receiver Dryer: Service and Repair 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. Filter/Drier Location 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. Liquid Line From Condenser 2. Remove liquid line at filter/drier from condenser. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 5873 Liquid Line From Expansion Valve 3. Remove liquid line at filter/drier from expansion valve. Liquid Line From Expansion Valve 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. INSTALLATION 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. - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Capacity ................................................................................................................................... ........................................ 0.74 kg (26 oz. or 1.63 lbs) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5878 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5879 Refrigerant: Description and Operation This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear 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 in a R-134a system could cause compressor failure, refrigerant oil sludging or poor performance. Never add R-12 to a system designed to use R.134a. System failure will occur. A/C Service Ports Both of the service ports to charge the air conditioning system are located on the hoses. New design of service ports have been used to ensure that the system is not accidentally filled with the wrong refrigerant (R-12). Refrigerant Recovery/Recycling Station Typical When servicing a system, it is required that an air conditioning charging recovery/recycling machine be used. Contact an automotive service equipment supplier for proper equipment. Refer to the operating instructions provided with the equipment for proper operation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5880 Manifold Gauge Set - Typical A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling device. Only use gauges that have not been used for R-12. The service hoses on the gauge set should have manual (turn wheel) or automatic back flow valves at the service port connector ends. This will prevent refrigerant R-134a from being released into the atmosphere. Underhood Label R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure that it is designed to be used in a R-134a system. Refer to the label under the hood for proper oil and refrigerant charge levels. Due to the different characteristics of R-134a it requires all new service procedures. 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 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-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. The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and low global warming impact. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Description and Operation Refrigerant Filter: Description and 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 drier is used to remove any traces of moisture from the refrigerant system. The filter is used to separate any foreign particles. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Description and Operation > Page 5884 Refrigerant Filter: Service and Repair 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. Filter/Drier Location 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. Liquid Line From Condenser 2. Remove liquid line at filter/drier from condenser. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Description and Operation > Page 5885 Liquid Line From Expansion Valve 3. Remove liquid line at filter/drier from expansion valve. 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. INSTALLATION 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. - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5890 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5891 Refrigerant Oil: Service and Repair 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 A/C Component Refrigerant Oil Capacities 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 table. 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 ND 8 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation Refrigerant Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION 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 screwed attached to a valve on the discharge line near the compressor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 5895 Refrigerant Pressure Sensor / Switch: Service and Repair 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. Hoist vehicle. 2. 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. Pressure Transducer (Viewed From Beneath Vehicle) 3. 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. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5901 Power Distribution Center, A/C Clutch Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 5902 Power Distribution Center, A/C Clutch Relay Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair Control Module HVAC: Service and Repair HVAC Control Module The control module is located below the radio. REMOVAL 1. Place the ignition key in the OFF position before removing control module. Control Module 2. Remove trim bezel. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Page 5906 6. Remove the control module retaining screws. 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 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. 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 1800 if the cable is properly adjusted. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams EVAP Temp Sensor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 5911 Evaporator Temperature Sensor / Switch: Description and Operation SYSTEM OPERATION 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 0.94 degree Celsius. (33.7 degree Fahrenheit). It is allowed to switch ON when the probe temperature reaches 2.05 degree Celsius. (35.7 degree Fahrenheit). The evaporator probe is located on the lower right side of the evaporator housing. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation Refrigerant Pressure Sensor / Switch: Description and Operation SYSTEM OPERATION 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 screwed attached to a valve on the discharge line near the compressor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 5915 Refrigerant Pressure Sensor / Switch: Service and Repair 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. Hoist vehicle. 2. 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. Pressure Transducer (Viewed From Beneath Vehicle) 3. 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. lbs.). Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation SYSTEM OPERATION The high pressure gauge port is located on the compressor discharge line. The low pressure gauge port is located on the suction line. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Specifications Thermal Limiter Switch: Specifications DESCRIPTION = TEMPERATURE Cut OFF Temperature = 122 to 128 degree Celsius (252 to 262 degree Fahrenheit) Cut IN Temperature = 104 to 116 degree Celsius (225 to 235 degree Fahrenheit) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Specifications > Page 5922 Thermal Limiter Switch: Description and Operation SYSTEM 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Specifications > Page 5923 Thermal Limiter Switch: Testing and Inspection 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 degree Celsius (252 to 262 degree Fahrenheit.) - Close circuit (continuity) at 106 to 116 degree Celsius (225 to 235 degree Fahrenheit.) There is no serviceability of the thermal limiter switch. If the thermal limiter switch fails, the compressor must be replaced. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Thermal Limiter Switch <--> [Thermal Limiting Fuse] > Component Information > Specifications > Page 5924 Thermal Limiter Switch: Service and Repair REMOVAL AND INSTALLATION 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 Replacement. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5932 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming NOTE: A DRB scan tool is required for diagnosis of the airbag system. Refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures for more information. ARMING 1. Make sure no one is in the vehicle. 2. Connect battery negative terminal. 3. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 4. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 5. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 6. Using the scan tool, read and record the active diagnostic trouble code data. 7. Read and record any stored diagnostic trouble codes. 8. Refer to the proper Passive Restraint Diagnostic Test if any diagnostic trouble codes are found in Step 6 and Step 7. 9. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Air Bags 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 Air Bags to diagnose the problem. To test the airbag warning lamp operation in the cluster only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5937 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations Air Bag: Component Locations Steering Column Connectors Dash Components Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Component Locations > Page 5940 Steering Column Connectors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page 5941 Air Bag: Diagrams Squib Connector Passenger Side Squib Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection Air Bag: Service and Repair Maintenance Inspection Check the airbag warning lamp for proper operation as follows: 1. Turn the ignition switch to the ON position. The airbag warning lamp should illuminate. If does not, test the system using a scan tool and Airbags Diagnostic Procedures. Repair as required. 2. The airbag warning lamp lights, but fails to go out after ten Seconds. Test the system using a scan tool and Airbags and Seatbelts/Airbags Diagnostic Procedures Diagnostic Procedures. Repair as required. 3. Erasing stored Diagnostic Trouble Codes is not required. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5944 Air Bag: Service and Repair Airbag Module Storage & Handling DEPLOYED MODULE The vehicle interior may contain a very small amount of sodium hydroxide powder, a by-product of airbag deployment. Sodium hydroxide powder can irritate the skin, eyes, nose and throat. Wear safety glasses, rubber gloves, and long sleeved clothing when cleaning any of the powder residue from the vehicle. If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. UNDEPLOYED The airbag module(s) must be stored in its original special container until used for service. At no time should a source of electricity be permitted near the inflator on the back of an airbag module. When carrying or handling an undeployed airbag module, the trim side of the airbag should be pointing away from the body to minimize possibility of injury if accidental deployment occurs. Do not place undeployed air-bag face down on a solid surface, the airbag will propel into the air if accidental deployment occurs. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5945 Air Bag: Service and Repair Driver Side Airbag Module Replacement REMOVAL 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. Driver Airbag Module 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 Replacement 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 Diagnosis and Testing for Airbag System Test procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5946 Air Bag: Service and Repair Passenger Side Airbag Module Replacement DEPLOYED MODULE 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5947 Instrument Panel Components 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5948 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. Alter removal of the instrument panel disconnect Passenger Airbag Module wire connector. 22. Remove the six Passenger 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. Transfer 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 Diagnosis and Testing for Airbag System Test procedures. UNDEPLOYED MODULE REMOVAL When removing a Passenger Airbag Module for any reason other than DEPLOYMENT. 1. Disconnect and isolate the battery negative remote cable. Passenger Airbag Removal 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 Diagnosis and Testing for Airbag System Test procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Maintenance Inspection > Page 5949 Air Bag: Service and Repair Service of Deployed Airbag Module DRIVER AIRBAG After a Driver Airbag Module has been deployed: Driver Airbag Module - Steering wheel - Clockspring assembly The component above must be replaced because they cannot be reused. Replace any other driver airbag system components if damaged. PASSENGER AIRBAG After a Passenger Airbag Module has been deployed: Passenger Airbag Module - Instrument panel plastic retainer and steel reinforcement assembly The components above must be replaced because of visible or non visible structural damage. The glove box, top cover, cluster hood, steering column cover, right trim bezel and/or end cap, or any other components should be checked and replaced if damaged. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5953 Air Bag Control Module: Diagrams Air Bag Control Module Connector Air Bag Control Module Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5954 Air Bag Control Module: Description and Operation SYSTEM OPERATION Airbag Control Module The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The impact sensor acts as a threshold sensitive switch that completes a circuit when an impact provides sufficient deceleration. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. The ACM monitors the system to determine the system readiness. The ACM stores sufficient energy to deploy the airbags for approximately two Minutes after the battery is disconnected. The ACM contains on-board diagnostics, and illuminates the AIRBAG warning lamp in the cluster when a diagnostic trouble code occurs. The warning equipment is tested for a few Seconds every time the vehicle is started. Driver And Passenger Airbag Module WARNING: NEVER DISASSEMBLE THE DRIVER OR PASSENGER AIRBAG MODULE, THERE ARE NO SERVICEABLE PARTS WITH IN THE MODULE. Driver And Passenger Airbag The Driver Airbag Module located in the center of the steering wheel is the most visible part of the system. 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. 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 Airbag Module is mounted directly to the steering wheel. The Passenger Airbag Module is located beneath the decorative cover of the instrument panel, facing the passenger seat. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 5955 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 A IMPACT SENSOR WHICH 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. For a manual transmission, remove shifter knob and boot. 3. Remove the four attaching screws floor console. 4. Remove the four floor shifter mounting nuts. Airbag Control Module 5. Remove two rear module mounting nuts and remove module. INSTALLATION CAUTION: USE SUPPLIED NUTS ONLY - For installation, reverse the above procedures. 1. Position ACM (arrow pointing forward) on center tunnel area mounting studs. 2. Attach the two rear mounting nuts and tighten to 15 to 19 N.m (125 to 160 in. lbs.) torque. 3. DO NOT CONNECT battery negative remote cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5960 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5961 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5962 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5963 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5964 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5965 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5966 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5967 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5968 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5969 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5970 PARTS REQUIRED: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5971 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5972 POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5977 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5978 Steering Column Connectors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5979 Clockspring Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5980 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 which winds and unwinds with the steering wheel rotation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5981 Clockspring Assembly / Spiral Cable: Adjustments 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 Clockspring Installation. Do not connect the battery negative remote cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 5982 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL 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. 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 Diagnosis and Testing for Airbag System Test procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5987 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5988 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5989 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5990 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5991 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5996 Air Bag Control Module: Diagrams Air Bag Control Module Connector Air Bag Control Module Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5997 Air Bag Control Module: Description and Operation SYSTEM OPERATION Airbag Control Module The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The impact sensor acts as a threshold sensitive switch that completes a circuit when an impact provides sufficient deceleration. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. The ACM monitors the system to determine the system readiness. The ACM stores sufficient energy to deploy the airbags for approximately two Minutes after the battery is disconnected. The ACM contains on-board diagnostics, and illuminates the AIRBAG warning lamp in the cluster when a diagnostic trouble code occurs. The warning equipment is tested for a few Seconds every time the vehicle is started. Driver And Passenger Airbag Module WARNING: NEVER DISASSEMBLE THE DRIVER OR PASSENGER AIRBAG MODULE, THERE ARE NO SERVICEABLE PARTS WITH IN THE MODULE. Driver And Passenger Airbag The Driver Airbag Module located in the center of the steering wheel is the most visible part of the system. 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. 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 Airbag Module is mounted directly to the steering wheel. The Passenger Airbag Module is located beneath the decorative cover of the instrument panel, facing the passenger seat. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 5998 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 A IMPACT SENSOR WHICH 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. For a manual transmission, remove shifter knob and boot. 3. Remove the four attaching screws floor console. 4. Remove the four floor shifter mounting nuts. Airbag Control Module 5. Remove two rear module mounting nuts and remove module. INSTALLATION CAUTION: USE SUPPLIED NUTS ONLY - For installation, reverse the above procedures. 1. Position ACM (arrow pointing forward) on center tunnel area mounting studs. 2. Attach the two rear mounting nuts and tighten to 15 to 19 N.m (125 to 160 in. lbs.) torque. 3. DO NOT CONNECT battery negative remote cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6005 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming NOTE: A DRB scan tool is required for diagnosis of the airbag system. Refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures for more information. ARMING 1. Make sure no one is in the vehicle. 2. Connect battery negative terminal. 3. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 4. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 5. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 6. Using the scan tool, read and record the active diagnostic trouble code data. 7. Read and record any stored diagnostic trouble codes. 8. Refer to the proper Passive Restraint Diagnostic Test if any diagnostic trouble codes are found in Step 6 and Step 7. 9. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Air Bags 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 Air Bags to diagnose the problem. To test the airbag warning lamp operation in the cluster only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6011 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 (L4-2.4L VIN X (1998)) 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 6012 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6013 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6014 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6015 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6016 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6017 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 (L4-2.4L VIN X (1998)) 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 6018 detailed instruction sheet. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6019 PARTS REQUIRED: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6020 POLICY: Customer Satisfaction Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6021 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6022 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 (L4-2.4L VIN X (1998)) 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 6023 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6024 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6025 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6026 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6027 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 6032 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6041 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 (L4-2.4L VIN X (1998)) 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 6042 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6043 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6044 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6045 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6046 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 (L4-2.4L VIN X (1998)) 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 6047 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 (L4-2.4L VIN X (1998)) 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 6048 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6049 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6050 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6051 PARTS REQUIRED: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 6052 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 (L4-2.4L VIN X (1998)) 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 6053 POLICY: Information Only Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Page 6071 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Testing and Inspection > Manual Antenna > Page 6074 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Manual Antenna and Mast > Page 6077 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Manual Antenna and Mast > Page 6078 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Diagrams Door Sensor/Switch (For Alarm): Diagrams Left Key Cylinder Switch Connector Right Key Cylinder Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 6083 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Adjustments Keyless Entry Module: Adjustments The scan tool (DRB) and the transmitter must be used to program the Remote Keyless Entry Module. Refer to the scan tool (DRB) for the procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Description and Operation Keyless Entry Transmitter Battery: Description and Operation SYSTEM OPERATION Transmitter Battery The transmitter has two 3 volt batteries, which can be removed and replaced without special tools. The battery is available at local retail stores. Recommended batteries are Toshiba CR2016 or equivalent. Battery life is about one to two years. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6099 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6100 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6101 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6106 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6107 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6108 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 (L4-2.4L VIN X (1998)) 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 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6113 Amplifier: Testing and Inspection Radio Connectors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6114 Amplified Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6115 Amplified Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6116 Amplified Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6117 Amplified Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6118 Amplified Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6119 Amplifier: Service and Repair REMOVAL 1. Remove the right front seat. Amplifier Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Description and Operation CD Changer: Description and Operation SYSTEM OPERATION The remote CD changer is located in the center console and is capable of holding up to six discs in a magazine. The magazine can be ejected at anytime that the ignition switch is in the ON position. After the ignition switch is turned OFF, the magazine can only be ejected within one minute . After that period, the magazine will be locked in the CD changer. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Description and Operation > Page 6124 CD Changer: Testing and Inspection DIN Cable Connector DIN Cable Pin-Outs Error Messages CD changer inoperative. 1. The CD changer receives its power and ground through the radio via the DIN cable. Verify that the radio powers up and functions before proceeding. 2. With the radio turned ON, check the radio display when pushing the MODE/EJECT button to select the CD mode. a. If the display shows - - - -,then insert a CD magazine in the changer. b. If the display shows nocd, then insert a CD into the magazine. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Description and Operation > Page 6125 c. If the display shows Err xxxx, then check the Error Message table below. d. If the radio only switches between AM and FM turning modes, then perform the following: I. Check the connection of the DIN cable to the CD changer and radio. II. If OK, then check the DIN cable at the CD changer side. III. Make sure the DIN cable is connected to the radio and radio is turned ON and operating properly Check for battery voltage at Pins 6 and 8 using Pin 8 for ground. IV. If OK, then replace CD changer. V. If not OK, then remove DIN cable from radio and changer. Check DIN cable for continuity from connector to connector, using a ohmmeter on each Pin. VI. If the DIN cable OK, then replace the radio. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Description and Operation > Page 6126 CD Changer: Service and Repair REMOVAL 1. Turn ignition switch to the OFF position. 2. Remove the instrument cluster hood. 3. Remove the two CD changer attaching screws located under the HVAC control. 4. Slide the CD changer/power outlet assembly rearward in the vehicle. 5. Disconnect CD DIN cable, power outlet, and the light socket assembly wire connectors. 6. Remove the CD changer. 7. Remove mounting bracket and power outlet from cd changer. Transfer to new unit if replacing changer. INSTALLATION - For installation, reverse the above procedure. Be sure to index rear tab on changer mounting bracket into slot in vehicle mounting bracket. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Locations Radio Connectors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 Radio/Stereo: Electrical Diagrams Standard Radio Audio Systems (Part 2 Of 3) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Premium Radio Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 Audio System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 Audio System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 Audio System NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6153 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. Remote CD Changer The remote CD changer is located in the center console and is capable of holding up to six discs in a magazine. The magazine can be ejected at anytime that the ignition switch is in the ON position. After the ignition switch is turned OFF, the magazine can only be ejected within one minute . After that period, the magazine will be locked in the CD changer. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 6154 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection Speaker: Testing and Inspection Radio Connectors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Page 6158 Base 6 Speaker System Diagnosis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Page 6159 Base 6 Speaker System Diagnosis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Testing and Inspection > Page 6160 Base 6 Speaker System Diagnosis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Rear Speaker > Page 6163 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Rear Speaker > Page 6164 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 Speaker 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Adjustments Keyless Entry Module: Adjustments The scan tool (DRB) and the transmitter must be used to program the Remote Keyless Entry Module. Refer to the scan tool (DRB) for the procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams Door Sensor/Switch (For Alarm): Diagrams Left Key Cylinder Switch Connector Right Key Cylinder Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Page 6173 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Compass/Mini-Trip Computer Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions Trip Computer: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 Compass/Mini-Trip Computer Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 Compass/Mini Trip Computer Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 6202 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 6203 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 6204 Trip Computer: Testing and Inspection 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams > Page 6205 Trip Computer: Service and Repair REMOVAL 1. Disconnect the battery negative cable. 2. Remove the Cluster Hood. Refer to Cluster Hood removal procedure. CMTC Module 3. With the cluster hood removed remove the four screws attaching the mini computer. 4. Remove CMTC from console. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations ETACS-ECU Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 6212 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 6213 Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 Body Control Module: Connector Views BCM Connector BCM Connector BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 BCM Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 Body Control Module: Electrical Diagrams Body Control Module Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 CCD Bus Wiring Diagrams Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 Body Control Module (Part 1 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 Body Control Module (Part 2 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 Body Control Module (Part 3 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 Body Control Module (Part 4 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 Body Control Module (Part 5 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 Body Control Module (Part 6 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Body Control Module (Part 7 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 Body Control Module (Part 8 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 Body Control Module (Part 9 Of 10) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 Body Control Module (Part 10 Of 10) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Description Body Control Module: Description and Operation Description 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, the airbag control module (ACM), the smart key immobilized system (SKIM) and the antilock brake module (CAB). 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 - 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 - Power top inhibit (JX) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Description > Page 6249 Body Control Module: Description and Operation Introduction 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics 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. 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. Diagnostic Strategies VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis of the body system is done in six basic steps: Verification Of Complaint - Verification Of Any Related Symptoms - Symptom Analysis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 6252 - Problem Isolation - Repair Of Isolated Problem - Verification Of Proper Operation Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 6253 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 6264 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications Cross-Member: Specifications FRONT: To Body Attaching Bolts ...................................................................................................................... ............................................ 163 Nm (120 ft. lbs.) REAR: To Body Attaching Bolts ...................................................................................................................... ................................................ 95 Nm (70 ft. lbs.) Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications > Page 6278 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6281 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6282 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6283 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. NOTE: When installing the lateral links on the crossmember, the lateral link attaching bolts must be installed as listed below. Install the forward lateral link to crossmember bolts so that the head of the bolt will be toward the front of the vehicle when the crossmember is installed. Install the rear lateral link to crossmember bolts so that the threaded end of the bolt will be facing toward the front of the vehicle when the crossmember is installed. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6284 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6285 8. Install muffler support bracket on rear frame rail. Install rear exhaust pipe hanger on rear suspension crossmember. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Removal > Page 6286 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6294 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming NOTE: A DRB scan tool is required for diagnosis of the airbag system. Refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures for more information. ARMING 1. Make sure no one is in the vehicle. 2. Connect battery negative terminal. 3. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 4. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 5. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 6. Using the scan tool, read and record the active diagnostic trouble code data. 7. Read and record any stored diagnostic trouble codes. 8. Refer to the proper Passive Restraint Diagnostic Test if any diagnostic trouble codes are found in Step 6 and Step 7. 9. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Air Bags 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 Air Bags to diagnose the problem. To test the airbag warning lamp operation in the cluster only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6303 Labor Operation No: 23-14-35-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6309 Labor Operation No: 23-14-35-96 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Ash Receiver/Cup Holder Lamp Bulb Replacement Drink Holders: Service and Repair Ash Receiver/Cup Holder Lamp Bulb Replacement 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Ash Receiver/Cup Holder Lamp Bulb Replacement > Page 6312 Drink Holders: Service and Repair Ash Receiver/Cup Holder Lamp Replacement 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Adjustments Keyless Entry Module: Adjustments The scan tool (DRB) and the transmitter must be used to program the Remote Keyless Entry Module. Refer to the scan tool (DRB) for the procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Description and Operation Keyless Entry Transmitter Battery: Description and Operation SYSTEM OPERATION Transmitter Battery The transmitter has two 3 volt batteries, which can be removed and replaced without special tools. The battery is available at local retail stores. Recommended batteries are Toshiba CR2016 or equivalent. Battery life is about one to two years. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Power Door Lock Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6333 Power Door Lock Actuator: Testing and Inspection Front Door Lock Motor 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. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 6334 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Key Cylinder Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 6338 Power Door Lock Switch: Diagrams Power Door Lock Switch Connector Power Door Lock Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 6339 Power Door Lock Switch: Testing and Inspection Remove the switch from its mounting location. Using an ohmmeter, test door lock switch continuity. Door Lock Switch Continuity Test Refer to the above image and move the switch to the Lock and Unlock positions. If the resistance values are not obtained, replace the switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 6340 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation Heated Element: Description and Operation SYSTEM OPERATION 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation > Page 6345 Heated Element: Testing and Inspection 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 (L4-2.4L VIN X (1998)) 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 in the, check for open or shorted circuit, or replace mirror assembly as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Page 6352 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Adjustments Keyless Entry Module: Adjustments The scan tool (DRB) and the transmitter must be used to program the Remote Keyless Entry Module. Refer to the scan tool (DRB) for the procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6385 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6386 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6387 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6388 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6389 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and Inspection Power Seat Motor: Testing and Inspection 1. Remove power seat switch from seat. 2. Disconnect wire harness connector. 3. Check Pin 5 for battery voltage and Pin 1 for ground. Switch Harness Connector 4. To test the seat motors, refer to the, 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 Switch Harness Connector Circuit Test table. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch: Testing and Inspection Switch Removal 1. Remove switch from mounting position. Power Seat Switch 2. Using an ohmmeter, perform the switch continuity tests. Refer to the Switch Continuity Test table. If there is no continuity in any of the switch positions, replace switch. 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. Using a voltmeter, connect the ground lead to Pin 5 of the switch harness connector. Connect the positive lead to Pin 1. If battery voltage is seen, the ground and B+ circuit is OK. If no voltage is seen, check the circuit breaker and repair as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 6396 Power Seat Switch: Service and Repair REMOVAL Switch Removal 1. Remove left cushion side shield. 2. Disconnect wiring from switch. 3. Remove the seat and recliner switch knobs. 4. Remove attaching screws and switch from bezel. INSTALLATION - For installation, reverse the above procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Key Cylinder Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 6401 Power Door Lock Switch: Diagrams Power Door Lock Switch Connector Power Door Lock Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 6402 Power Door Lock Switch: Testing and Inspection Remove the switch from its mounting location. Using an ohmmeter, test door lock switch continuity. Door Lock Switch Continuity Test Refer to the above image and move the switch to the Lock and Unlock positions. If the resistance values are not obtained, replace the switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 6403 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 6407 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 (L4-2.4L VIN X (1998)) 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 Switch Removal 1. Remove switch from mounting position. Power Seat Switch 2. Using an ohmmeter, perform the switch continuity tests. Refer to the Switch Continuity Test table. If there is no continuity in any of the switch positions, replace switch. 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. Using a voltmeter, connect the ground lead to Pin 5 of the switch harness connector. Connect the positive lead to Pin 1. If battery voltage is seen, the ground and B+ circuit is OK. If no voltage is seen, check the circuit breaker and repair as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 6411 Power Seat Switch: Service and Repair REMOVAL Switch Removal 1. Remove left cushion side shield. 2. Disconnect wiring from switch. 3. Remove the seat and recliner switch knobs. 4. Remove attaching screws and switch from bezel. INSTALLATION - For installation, reverse the above procedure. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 6416 Brake Switch (Cruise Control): Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch refer to Lighting and Horns/Brake Lamp/Stop Switch Replacement. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 6417 Brake Switch (Cruise Control): Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Speed Control Servo, Servo Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6421 Speed Control Servo Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6422 Cruise Control Servo: Description and Operation SYSTEM OPERATION The servo unit consists of a solenoid valve body, and a vacuum chamber. The Powertrain Control Module (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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6423 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 Replacement. 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 6427 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. Disconnecting Throttle Cable - Typical 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations On/Off Cancel, Set/Resume Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 6432 Steering Column Connectors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6433 Speed Control Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6434 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. 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. NOTE: Depressing the OFF switch or turning oft the ignition switch will erase the set speed stored in the PCM. For added safety,the speed control system is programmed to disengaged for 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 when speed is greater than 25 mph restores the vehicle to the target speed that was stored in the PCM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. While the speed control is engaged, the driver can increase the vehicle speed by depressing the RES/ACCEL switch. The new target speed is stored in the PCM when the RES/ACCEL 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 individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6435 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation Cruise Control Vacuum Reservoir: Description and Operation SYSTEM OPERATION The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. Vehicles with a 3 speed automatic or manual transmission have a vehicle speed sensor (VSS) mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Management/Computer and Control Systems/Test Procedures of this component. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Page 6439 Cruise Control Vacuum Reservoir: Testing and Inspection Servo Vacuum 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Page 6440 Cruise Control Vacuum Reservoir: Service and Repair The vacuum reservoir is located on the dash panel next to the brake booster. REMOVAL 1. Disconnect vacuum hoses from reservoir. 2. Pull vacuum reservoir from dash panel. INSTALLATION 1. Push reservoir onto dash panel. 2. Connect hoses to reservoir. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 6445 Brake Switch (Cruise Control): Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch refer to Lighting and Horns/Brake Lamp/Stop Switch Replacement. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 6446 Brake Switch (Cruise Control): Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations On/Off Cancel, Set/Resume Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Component Locations > Page 6451 Steering Column Connectors Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6452 Speed Control Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6453 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. 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. NOTE: Depressing the OFF switch or turning oft the ignition switch will erase the set speed stored in the PCM. For added safety,the speed control system is programmed to disengaged for 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 when speed is greater than 25 mph restores the vehicle to the target speed that was stored in the PCM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. While the speed control is engaged, the driver can increase the vehicle speed by depressing the RES/ACCEL switch. The new target speed is stored in the PCM when the RES/ACCEL 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 individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6454 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6463 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6469 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6472 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6481 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 6487 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Service and Repair > Vehicle Speed Sensor > Page 6490 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The ABS system uses a yellow colored ABS Warning Lamp. The ABS warning lamp is located on the left side of the instrument panel, in the instrument cluster next to the tachometer. The purpose of the warning lamp is discussed in detail below. The ABS warning lamp will turn on when the Controller Antilock Brakes (CAB) detects a condition which results in a shutdown of ABS function or when the body controller does not receive C2D messages from the CAB. When the ignition key is turned to the on position, the ABS Warning Lamp is on until the CAB completes its self tests and turns the lamp off (approximately 4 seconds after the ignition switch is turned on). Under most conditions, when the ABS warning lamp is on, only the ABS function of the brake system is affected. The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on. The ABS warning lamp is controlled by the CAB and the body controller through a diode located in the wiring harness junction block. The junction block is located under the instrument panel to the left of the steering column. The CAB controls the lamp by directly grounding the circuit. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 Chime System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test Revisions NUMBER: 26-12-97I GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013 DESCRIPTION OF CHANGES Revisions to the ABS warning lamp test Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6521 94 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6522 95 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6523 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6524 244 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 6525 245 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Page 6526 Brake Warning Indicator: Description and Operation Master Cylinder Fluid Level Sensor 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. 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 CAB. 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. If brake fluid level has dropped in master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 6552 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 (L4-2.4L VIN X (1998)) 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 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Replacement Compass: Service and Repair Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Remove the Cluster Hood. Refer to Cluster Hood removal procedure. CMTC Module 3. With the cluster hood removed remove the four screws attaching the mini computer. 4. Remove CMTC from console. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Replacement > Page 6557 Compass: Service and Repair Service Procedure Variance Setting 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. After five Seconds of inactivity, the displayed zone will be automatically set and normal operation in the Compass/Temperature mode resumed. Calibrate the compass by driving the vehicle in a circle with a constant speed between 5 and 11 MPH (8 and 18 Km/h), the diameter should be between 6 and 27.5 meters (30 and 90 feet). The speed of the vehicle should not vary no more than 3 MPH (5 Km/h) otherwise the calibration is aborted. To ensure that the compass has been properly calibrated, point the vehicle in each of the following four directions: (N), (S), (E), and (W). 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 1 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 5 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6564 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming NOTE: A DRB scan tool is required for diagnosis of the airbag system. Refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures for more information. ARMING 1. Make sure no one is in the vehicle. 2. Connect battery negative terminal. 3. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 4. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 5. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 6. Using the scan tool, read and record the active diagnostic trouble code data. 7. Read and record any stored diagnostic trouble codes. 8. Refer to the proper Passive Restraint Diagnostic Test if any diagnostic trouble codes are found in Step 6 and Step 7. 9. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Air Bags 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 Air Bags to diagnose the problem. To test the airbag warning lamp operation in the cluster only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 Door Ajar System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations Door Ajar Switch Door Ajar Switch Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 Door Switch: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Door Ajar System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Service and Repair Fuel Gauge: Service and Repair REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Service and Repair > Page 6613 Fuel Gauge And Temperature Gauge 4. Remove the fuel/temperature gauge attaching screws from the housing and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications Sending Unit Resistance Chart Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6623 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming NOTE: A DRB scan tool is required for diagnosis of the airbag system. Refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures for more information. ARMING 1. Make sure no one is in the vehicle. 2. Connect battery negative terminal. 3. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 4. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 5. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 6. Using the scan tool, read and record the active diagnostic trouble code data. 7. Read and record any stored diagnostic trouble codes. 8. Refer to the proper Passive Restraint Diagnostic Test if any diagnostic trouble codes are found in Step 6 and Step 7. 9. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Air Bags 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 Air Bags to diagnose the problem. To test the airbag warning lamp operation in the cluster only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 6628 Odometer: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 6629 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations 2.4L Engine Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Door Ajar Switch Door Ajar Switch Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Door Switch: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Door Ajar System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Sending Unit Resistance Chart Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Service and Repair Speedometer Head: Service and Repair REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Service and Repair > Page 6663 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Service and Repair Tachometer: Service and Repair REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Service and Repair > Page 6667 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Service and Repair Temperature Gauge: Service and Repair REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Service and Repair > Page 6671 Fuel Gauge And Temperature Gauge 4. Remove the fuel/temperature gauge attaching screws from the housing and remove. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 6676 Transmission Mode Indicator - A/T: Service and Repair Speedometer/Tachometer/Odometer/Transmission Range Indicator REMOVAL Mask/Lens Retaining Screw 1. Remove mask/lens retaining screws and remove mask/lens. Back Covering 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Odometer/Transmission Range Indicator > Page 6677 Junction Block/BCM Location 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb Transmission Shift Position Indicator Lamp: Service and Repair Floor PRNDL Bezel Lamp Bulb REMOVAL AND INSTALLATION The floor PRNDL bezel lamp has no serviceable bulb. If the lamp does not function properly, the PRNDL bezel assembly must be replaced. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Service and Repair > Floor PRNDL Bezel Lamp Bulb > Page 6682 Transmission Shift Position Indicator Lamp: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair REMOVAL 1. Release trunk latch and open trunk lid. 2. Remove wing-nuts holding tail tamp 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Lamp Switch, Brake Lamp Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6695 Brake Lamp Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6696 Brake Light 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6697 Brake Light 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6698 Brake Light Switch: Adjustments 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. Stop Light Switch Location In Vehicle 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6699 Brake Light Switch: Service and Repair REMOVE Stop Light Switch Location In Vehicle 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Service and Repair > Ash Receiver/Cup Holder Lamp Bulb > Page 6709 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Glove Box Lamp > Page 6714 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation SYSTEM OPERATION Daytime Running Lamp Module Daytime Running Lamp (CANADA) JA vehicles built for use ill Canada are equipped with a Daytime Running Lamp (DRL) system. The DRL system operates the headlamps at 50% illumination with the headlamp switch OFF, park brake released and the ignition ON. The DRL system is controlled by the Daytime Running Lamp Module located on the back of the multi-function module behind the instrument panel. The DRL module overrides the headlamp switch when the headlamps are turned OFF. The headlamps operate normally when the headlamps are turned ON. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 6721 Battery Discharge Protection Relay: Description and Operation SYSTEM OPERATION 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Door Ajar Switch Door Ajar Switch Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 Door Switch: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 Door Ajar System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 behind 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 6760 Combination Flasher Diagnosis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 6761 Hazard Warning Flasher: Service and Repair REMOVAL AND INSTALLATION Combination Flasher Location 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 Column/Steering Column Cover replacement. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation GENERAL INFORMATION 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. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Page 6765 Hazard Warning Switch: Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Page 6766 Hazard Warning Switch: Service and Repair 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 (L4-2.4L VIN X (1998)) 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 6771 Headlamp Bulb 7. Pull bulb from headlamp module. INSTALLATION - Reverse the preceding operation. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 headlamp 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 6778 Headlamp Dimmer Switch: Service and Repair REMOVAL AND INSTALLATION The headlamp dimmer switch is incorporated into the turn signal switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection Headlamp Relay: Testing and Inspection For test of headlamp relay use a known good relay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6786 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. See the Diagnosis and Testing for more information on the operation of the horn relay. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6787 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6788 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Testing and Inspection > Page 6792 Horn Switch: Service and Repair Horn Contact Switch 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Description and Operation 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair REMOVAL License Plate Lamp Bulb 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 park and turn signal lamp to headlamp module. 3. Separate lamp from module from radiator closure panel. 4. Remove bulb socket from back of lamp. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 6812 Battery Discharge Protection Relay: Description and Operation SYSTEM OPERATION 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 headlamp 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection Headlamp Relay: Testing and Inspection For test of headlamp relay use a known good relay. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6822 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. See the Diagnosis and Testing for more information on the operation of the horn relay. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6823 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6824 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Lamp Switch, Brake Lamp Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6829 Brake Lamp Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6830 Brake Light 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6831 Brake Light 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6832 Brake Light Switch: Adjustments 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. Stop Light Switch Location In Vehicle 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6833 Brake Light Switch: Service and Repair REMOVE Stop Light Switch Location In Vehicle 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Door Ajar Switch Door Ajar Switch Door Ajar Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 Circuit Function Circuit Identification Code Chart 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 Wire Code Identification 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 CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 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. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. 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. - 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 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. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location 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 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 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. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 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. 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 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-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Wiring Repair Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6853 Door Switch: 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6854 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6855 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6856 Door Ajar System Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation GENERAL INFORMATION 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. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 6863 Hazard Warning Switch: Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 6864 Hazard Warning Switch: Service and Repair 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 6868 Headlamp Dimmer Switch: Service and Repair REMOVAL AND INSTALLATION The headlamp dimmer switch is incorporated into the turn signal switch. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Testing and Inspection > Page 6872 Horn Switch: Service and Repair Horn Contact Switch 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 6876 Turn Signal Switch: Description and Operation GENERAL INFORMATION 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. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 6877 Turn Signal Switch: Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 6878 Turn Signal Switch: Service and Repair 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation Turn Signal 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. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 6887 Combination Flasher Diagnosis Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 6888 Turn Signal Flasher: Service and Repair REMOVAL AND INSTALLATION Combination Flasher Location 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 Column/Steering Column Cover replacement. 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 (L4-2.4L VIN X (1998)) 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 park and turn signal lamp to headlamp module. 3. Separate lamp from module from radiator closure panel. 4. Remove bulb socket from back of lamp. 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 (L4-2.4L VIN X (1998)) 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 6894 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 6898 Turn Signal Switch: Description and Operation GENERAL INFORMATION 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. When the system is activated, one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps, indicating to the driver that the system is operating. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 6899 Turn Signal Switch: Testing and Inspection 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 6900 Turn Signal Switch: Service and Repair 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass Element Relay > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass Element Relay > Component Information > Locations > Page 6906 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 13 for battery voltage. If voltage is OK, go to Step 2. If voltage is not OK, repair A4 circuit. b. Test the rear window defogger relay terminal for battery voltage with the key in the run position. If voltage is OK, go to Step 3. If voltage is not OK, repair A31 circuit. c. Use a known good relay. If not OK, repair circuits as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Heated Glass Element Relay > Component Information > Locations > Page 6907 Heated Glass Element Relay: Service and Repair REMOVAL AND INSTALLATION 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Customer Interest for Rear Defogger: > 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Junction Block Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6925 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 13 for battery voltage. If voltage is OK, go to Step 2. If voltage is not OK, repair A4 circuit. b. Test the rear window defogger relay terminal for battery voltage with the key in the run position. If voltage is OK, go to Step 3. If voltage is not OK, repair A31 circuit. c. Use a known good relay. If not OK, repair circuits as necessary. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 6926 Heated Glass Element Relay: Service and Repair REMOVAL AND INSTALLATION 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 (L4-2.4L VIN X (1998)) 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 Continuity Test Passenger Window Switch Continuity Test For switch testing, remove the switch from its mounting, refer to Switch Removal. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 6931 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 Power Window Switch Passenger Switch 1. Remove passenger door trim panel. 2. Disconnect switch wire connector. 3. Using a trim stick (special tool #C-4755), gently pry out switch from bezel being careful not to damage bezel. INSTALLATION Master Switch and Passenger Switch For installation, reverse the the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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, replace motor. See below for motor removal from vehicle. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Testing and Inspection > Page 6936 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Master Window Switch Continuity Test Passenger Window Switch Continuity Test For switch testing, remove the switch from its mounting, refer to Switch Removal. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 6940 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 Power Window Switch Passenger Switch 1. Remove passenger door trim panel. 2. Disconnect switch wire connector. 3. Using a trim stick (special tool #C-4755), gently pry out switch from bezel being careful not to damage bezel. INSTALLATION Master Switch and Passenger Switch For installation, reverse the the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 6950 Windshield Washer Switch: Description and Operation GENERAL INFORMATION Multi-Function Switch WARNING: VEHICLES ARE EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR STEERING WHEEL OR COLUMN SERVICE PROCEDURES. Multi-Function 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. To use the washers pull lever toward the driver. The mist is a single wipe operation by pushing lever down and releasing the lever. Intermittent wiper operation is controlled by the Body Control Module (BCM). The lever has a selection of delay intervals and by turning lever the wiper will cycle every half Second to 36 Seconds depending ON the vehicle's speed. The wiper has two cycle two speeds. The windshield wipers will only operate when the ignition switch is in the ACCESSORY or IGNITION position. Fuse 15, located in the Junction Block, fuses 8 and 14 in the Power Distribution Center block, protects the wiper/washer system circuitry The wiper motor also has an internal non-serviceable circuit breaker to provide protection against motor stall conditions The wiper and washer motors have magnetic fields created by internal permanent magnet. Electric power applied to the motor armature, located in the magnetic field, causes the motor to turn. The wiper system internal operation uses the low speed motor circuit in combination with intermittent wipe relay. The washer pump motor has one internal circuit and therefore operates at one speed. The wiper and washer system switch located on the steering column selects the mode of operation of the motors. The switch provides input to the BCM, which in turn operates the two relays. The intermittent wipe relay turns the wiper ON and OFF. The other changes the HIGH/LOW speeds. The switch also provides power to the washer pump motor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 6951 The intermittent wiper system, in addition to low and high speed, has a delay mode. The delay mode has a range of 1/2 to 18 Seconds when the vehicle speed is over 10 mph The wiper delay times will automatically double to a range of 1 to 36 Seconds when the vehicle speed is less than 10 mph The delay is controlled by a variable resistor in the wiper switch and BCM. The wiper motor and washer motor are designed to reduce radio frequency interference and provide electro-magnetic compatibility (RFI/EMC) in the vehicle environment. This is done with suppression circuits designed into the motors. The wiper system completes the wipe cycle when the switch is turned OFF. The blades park in the lowest portion of the wipe pattern. When using a scan tool (DRB) refer to the Body Diagnostic for the procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 6952 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering ad Suspension/steering column/steering column cover removal procedures below. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6956 Wiper Switch: Description and Operation GENERAL INFORMATION Multi-Function Switch WARNING: VEHICLES ARE EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR STEERING WHEEL OR COLUMN SERVICE PROCEDURES. Multi-Function 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. To use the washers pull lever toward the driver. The mist is a single wipe operation by pushing lever down and releasing the lever. Intermittent wiper operation is controlled by the Body Control Module (BCM). The lever has a selection of delay intervals and by turning lever the wiper will cycle every half Second to 36 Seconds depending ON the vehicle's speed. The wiper has two cycle two speeds. The windshield wipers will only operate when the ignition switch is in the ACCESSORY or IGNITION position. Fuse 15, located in the Junction Block, fuses 8 and 14 in the Power Distribution Center block, protects the wiper/washer system circuitry The wiper motor also has an internal non-serviceable circuit breaker to provide protection against motor stall conditions The wiper and washer motors have magnetic fields created by internal permanent magnet. Electric power applied to the motor armature, located in the magnetic field, causes the motor to turn. The wiper system internal operation uses the low speed motor circuit in combination with intermittent wipe relay. The washer pump motor has one internal circuit and therefore operates at one speed. The wiper and washer system switch located on the steering column selects the mode of operation of the motors. The switch provides input to the BCM, which in turn operates the two relays. The intermittent wipe relay turns the wiper ON and OFF. The other changes the HIGH/LOW speeds. The switch also provides power to the washer pump motor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6957 The intermittent wiper system, in addition to low and high speed, has a delay mode. The delay mode has a range of 1/2 to 18 Seconds when the vehicle speed is over 10 mph The wiper delay times will automatically double to a range of 1 to 36 Seconds when the vehicle speed is less than 10 mph The delay is controlled by a variable resistor in the wiper switch and BCM. The wiper motor and washer motor are designed to reduce radio frequency interference and provide electro-magnetic compatibility (RFI/EMC) in the vehicle environment. This is done with suppression circuits designed into the motors. The wiper system completes the wipe cycle when the switch is turned OFF. The blades park in the lowest portion of the wipe pattern. When using a scan tool (DRB) refer to the Body Diagnostic for the procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6958 Wiper Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering ad Suspension/steering column/steering column cover removal procedures below. 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Washer Fluid Switch Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 6962 Washer Fluid Pump Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 6963 Windshield Washer Pump: Service and Repair REMOVAL 1. Partially remove the bumper fascia 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 (L4-2.4L VIN X (1998)) 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 fascia as needed to gain access to the reservoir. Reservoir Removal 3. Disconnect wire connector from washer pump and harness mounting tab. 4. Slide rearward and drop down and away from vehicle. 5. Drain washer fluid from reservoir into an appropriate container. 5. Disconnect the washer hose from the reservoir. INSTALLATION - For installation, reverse the above procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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. INSTALLATION Wiper Blade And Element 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 6973 Windshield Washer Switch: Description and Operation GENERAL INFORMATION Multi-Function Switch WARNING: VEHICLES ARE EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR STEERING WHEEL OR COLUMN SERVICE PROCEDURES. Multi-Function 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. To use the washers pull lever toward the driver. The mist is a single wipe operation by pushing lever down and releasing the lever. Intermittent wiper operation is controlled by the Body Control Module (BCM). The lever has a selection of delay intervals and by turning lever the wiper will cycle every half Second to 36 Seconds depending ON the vehicle's speed. The wiper has two cycle two speeds. The windshield wipers will only operate when the ignition switch is in the ACCESSORY or IGNITION position. Fuse 15, located in the Junction Block, fuses 8 and 14 in the Power Distribution Center block, protects the wiper/washer system circuitry The wiper motor also has an internal non-serviceable circuit breaker to provide protection against motor stall conditions The wiper and washer motors have magnetic fields created by internal permanent magnet. Electric power applied to the motor armature, located in the magnetic field, causes the motor to turn. The wiper system internal operation uses the low speed motor circuit in combination with intermittent wipe relay. The washer pump motor has one internal circuit and therefore operates at one speed. The wiper and washer system switch located on the steering column selects the mode of operation of the motors. The switch provides input to the BCM, which in turn operates the two relays. The intermittent wipe relay turns the wiper ON and OFF. The other changes the HIGH/LOW speeds. The switch also provides power to the washer pump motor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 6974 The intermittent wiper system, in addition to low and high speed, has a delay mode. The delay mode has a range of 1/2 to 18 Seconds when the vehicle speed is over 10 mph The wiper delay times will automatically double to a range of 1 to 36 Seconds when the vehicle speed is less than 10 mph The delay is controlled by a variable resistor in the wiper switch and BCM. The wiper motor and washer motor are designed to reduce radio frequency interference and provide electro-magnetic compatibility (RFI/EMC) in the vehicle environment. This is done with suppression circuits designed into the motors. The wiper system completes the wipe cycle when the switch is turned OFF. The blades park in the lowest portion of the wipe pattern. When using a scan tool (DRB) refer to the Body Diagnostic for the procedures. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 6975 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect battery negative cable. 2. Remove the upper steering column cover. Refer to Steering ad Suspension/steering column/steering column cover removal procedures below. 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 (L4-2.4L VIN X (1998)) 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. Position arm on windshield and tighten to 33 to 40 N.m (23 to 29 ft. lbs.) torque. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) 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 blade with wiper location made on windshield 2. Start retention nut. 3. Raise arm and blade off windshield while tightening retention nut. Tighten nut to 33 to 40 N mm (23 to 29 ft. lbs.). 4. Install arm head cover. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm and Blade > Page 6981 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 6995 Wiper Blade: Description and Operation SYSTEM OPERATION Wiper Blade - Typical When the wiper blade rubber element is exposed to the weather for a long period of time, it tends to lose wiping ability. Periodic cleaning of the wiper blade element is suggested to remove the accumulation of salt and road film. The wiper blades, arms, and windshield should be cleaned with a sponge or cloth and a mild detergent or non-abrasive cleaner. If the blades continue to streak or smear, they should be replaced. The driver and the passenger blade elements are 550 mm in length. Only the driver's side wiper blade has a air foil on it. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 6996 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 Alignment. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm and Blade 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 blade with wiper location made on windshield 2. Start retention nut. 3. Raise arm and blade off windshield while tightening retention nut. Tighten nut to 33 to 40 N mm (23 to 29 ft. lbs.). 4. Install arm head cover. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm and Blade > Page 6999 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, then turn ignition switch OFF. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm and Blade > Page 7000 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 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 Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm and Blade > Page 7001 3. Ensure that the final blade claw is locked into the slot at the end of the rubber element. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Windshield Wiper Motor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 7005 Wiper Motor Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 7006 Wiper Motor: Testing and Inspection Wiper Motor Test WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, SEE AIRBAGS AND SEATBELTS/AIRBAGS 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 table. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Replacement Wiper Motor: Service and Repair Replacement WIPER MOTOR REMOVAL Wiper Module 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. WIPER 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. MOTOR ASSEMBLY REMOVAL 1. Remove wiper arms and blades. 2. Remove the cowl screen. 3. Remove wiper motor assembly Linkage Removal Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Replacement > Page 7009 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 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. Tighten the motor mounting nuts to 25 to 30 N.m (19 to 23 ft. lbs.) torque. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Replacement > Page 7010 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 (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi Function Switch Connector Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7017 Wiper Switch: Description and Operation GENERAL INFORMATION Multi-Function Switch WARNING: VEHICLES ARE EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR STEERING WHEEL OR COLUMN SERVICE PROCEDURES. Multi-Function 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. To use the washers pull lever toward the driver. The mist is a single wipe operation by pushing lever down and releasing the lever. Intermittent wiper operation is controlled by the Body Control Module (BCM). The lever has a selection of delay intervals and by turning lever the wiper will cycle every half Second to 36 Seconds depending ON the vehicle's speed. The wiper has two cycle two speeds. The windshield wipers will only operate when the ignition switch is in the ACCESSORY or IGNITION position. Fuse 15, located in the Junction Block, fuses 8 and 14 in the Power Distribution Center block, protects the wiper/washer system circuitry The wiper motor also has an internal non-serviceable circuit breaker to provide protection against motor stall conditions The wiper and washer motors have magnetic fields created by internal permanent magnet. Electric power applied to the motor armature, located in the magnetic field, causes the motor to turn. The wiper system internal operation uses the low speed motor circuit in combination with intermittent wipe relay. The washer pump motor has one internal circuit and therefore operates at one speed. The wiper and washer system switch located on the steering column selects the mode of operation of the motors. The switch provides input to the BCM, which in turn operates the two relays. The intermittent wipe relay turns the wiper ON and OFF. The other changes the HIGH/LOW speeds. The switch also provides power to the washer pump motor. Dodge Stratus Workshop Manual (L4-2.4L VIN X (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7018 The intermittent wiper system, in addition to low and high speed, has a delay mode. The delay mode has a range of 1/2 to 18 Seconds when the vehicle speed is over 10 mph The wiper delay times will automatically double to a range of 1 to 36 Seconds when the vehicle speed is less than 10 mph The delay is controlled by a variable resistor in the wiper switch and BCM. The wiper motor and washer motor are designed to reduce radio frequency interference and provide electro-magnetic compatibility (RFI/EMC) in the vehicle environment. This is done with suppression circuits designed into the motors. The wiper system completes the wipe cycle when the switch is turned OFF. The blades park in the lowest portion of the wipe pattern. When using a scan tool (DRB) refer to the Body Diagnostic for the procedures.

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